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ICE & PP Lab Report 6

The lab report details the disassembly and measurement of a Toyota 2F gasoline engine piston and cylinder assembly. The objectives included measuring the cylinder bore diameter and assessing wear using a bore gauge. The report emphasizes safety precautions and outlines the procedures for both disassembly and assembly of engine components.

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Waleed Nasir
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25 views6 pages

ICE & PP Lab Report 6

The lab report details the disassembly and measurement of a Toyota 2F gasoline engine piston and cylinder assembly. The objectives included measuring the cylinder bore diameter and assessing wear using a bore gauge. The report emphasizes safety precautions and outlines the procedures for both disassembly and assembly of engine components.

Uploaded by

Waleed Nasir
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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IC Engines and Power Plants Lab

Lab Report 06
Detail Summary on Gasoline Engine Piston

& Cylinder Assembly (Toyota 2F)

8th SEMESTER

Session: 2021
Section: C
Submitted To: LE Muhammad Usman Ghani

SUBMITTED BY
Name CMS ID

Waleed Nasir 394281

School of Mechanical and Manufacturing Engineering


OBJECTIVE
 Remove the oil sump, take out the piston with the connecting rod, and measure the cylinder bore
diameter.
 Measure the cylinder at different points to check uniformity and wear and find the average bore
gauge deflection.

EQUIPMENT & APPARATUS


 Socket Set
 LN Key Set
 Spanner Set
 Wrench
 Ring Spanner Set
 Ratchet
 Bore Gauge
 Torque Wrench
 Micrometre screw gauge

Theoretical Background:
The SI engine examined is a 6-cylinder, 4-stroke petrol engine equipped with a carburetor namely the
Toyota 2F engine. It features six intake and six exhaust ports, with each cylinder having one of each.
The outermost ports serve as exhaust ports, while the intake and exhaust ports alternate.
Disassembled Parts Description

Engine Head:
The engine head of the Toyota 2F engine houses the valve spring assembly, spark plugs, pushrods for
transferring motion from the camshaft to the rocker arms, coolant passages, and the rocker arm
assembly. The camshaft is integrated into the engine block, making it not directly visible. This
configuration is known as an overhead valve (OHV) design, where the valves are positioned above the
camshaft. The engine has a total of 12 valves, with each cylinder having one intake and one exhaust
valve.

Valve Spring Assembly


The valve spring assembly consists of the valve itself, a valve spring that keeps it in position when not
activated, a metal cap known as the valve retainer, and valve keepers that lock the valve in place.
Pushrods
Pushrods convert the rotational motion of the camshaft into linear motion, enabling the rocker arms to
open and close the valves according to the required timing.

Coolant Passages
Coolant passages within the engine head help dissipate heat and prevent engine overheating.

Rocker Arm Assembly


The rocker arm assembly is operated by the pushrods to control the valves. It consists of a metal shaft
that supports the rocker arms, rocker arm springs and spacers for adjusting the distance between arms,
and rocker arm pedestals that secure the assembly to the engine head

Oil Sump:
The oil sump collects oil as it drains from various engine components. It is fastened to the engine block
using bolts on both sides. Once these bolts are removed, the oil sump can be easily detached and set
aside.

Piston:
Once the engine head is detached, the piston is removed from the exposed engine block. The piston,
made of cast aluminum, moves back and forth as combustion takes place within the combustion
chamber.

Disassembly:

1. Loosen the sump bolts using a 13mm ring spanner.


2. Remove all the sump bolts and set the sump aside.
3. Secure the rocker arm assembly in a lifted position, then extract all the pushrods.
4. Unbolt the engine head with a 14mm socket, torque wrench, and extension.
5. Carefully detach the engine head and place it safely to reveal the pistons.
6. Unscrew the bolts securing the connecting rod to the crankshaft to free the piston and rod.
7. Using the reverse side of a hammer, gently tap the piston from below to extract it.

Measurement Procedure:

1. Use Vernier calipers to measure the bore diameter, which was recorded as 94mm.
2. Attach a 94mm extension to the bore gauge, calibrate its dial to zero at 94mm, and insert it into
the cylinder.
3. Move the bore gauge within the cylinder to assess the average wear based on needle deflection.
4. The needle deflection was recorded at 0.02mm.
5. Repeat the process for another provided cylinder.
6. Attach an additional 3mm washer to approximate its bore size to 98mm.
7. Set the screw gauge to 98mm, adjust the bore gauge to zero, and measure the bore diameter,
which was recorded as 97.92 mm.
Assembly:

1. Carefully insert the piston into the cylinder and gently tap it downward using the reverse side of
a hammer.
2. Align the connecting rod with the crankshaft and secure it by tightening the bolts.
3. Place the engine head onto the engine block and fasten it using a 14mm socket, torque wrench,
and extension.
4. Insert all pushrods into their designated positions.
5. Mount the rocker arm assembly onto the engine head and secure it properly.
6. Position the oil sump beneath the engine block, ensuring proper alignment.
7. Tighten all sump bolts with a 13mm ring spanner to create a secure seal.
DISCUSSION
The Toyota 2F 6-cylinder engine was disassembled as needed to access the cylinder liners. A
piston and its connecting rod were removed to measure cylinder wear. We learned how to
operate the bore gauge and interpret its deflection to identify wear and variations in cylinder
diameter. The process required removing the oil sump to access the bolts securing the
connecting rod to the crankshaft. The engine head was also detached to allow piston removal.
This was a detailed exercise that covered disassembly, assembly, and wear measurement.

Lab Safety Precautions:


 Always wear personal protective equipment (PPE), including safety goggles, gloves,
and ear protection.
 Handle fuel carefully and avoid ignition sources.
 Use an exhaust extraction system to direct emissions safely.
 Never open the radiator cap when the engine is hot.
 Keep a fire extinguisher nearby and be aware of emergency shutdown procedures.
 Ensure the lab is well-ventilated to prevent carbon monoxide buildup.
 Keep hands, clothing, and tools away from moving engine parts.
 Every work should be done under supervision of the instructor.
 Wear proper shoes so nothing falling like a sharp metal piece or nut could cause harm.

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