IC Engines and Power Plant Lab Lab

LAB 03

Dismantling of 6 Cylinder SI Engine

Lab Supervisor: Engr. Usman Ghani

Submitted by
Name Abdul Qadir
Cmsid 369921
Session ME 13
Section C
Semester 8th

National University of Sciences and technology

School of Mechanical and Manufacturing Engineering (SMME)

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Objectives:
• To learn in-depth about the different components of Petrol engine
• Identify the different tools with which to de-assemble various components of a petrol engine.
• Use those tools to take down components and sub-systems of the Toyota 2F engine and then properly
assemble them again.

Introduction:
The Toyota 2F engine is a 6-cylinder, inline, spark-ignition (SI) engine that has been widely used in Toyota
Land Cruisers. Known for its durability and reliability, the 2F engine is a classic example of a naturally
aspirated, carbureted engine. It features a cast-iron block and head, overhead valves (OHV), and a simple yet
powerful design. The engine operates on the four-stroke cycle: intake, compression, power, and exhaust.
In this lab, we dismantled a Toyota 2F engine to understand its internal components, their functions, and the
working mechanism of the engine as a whole. The dismantling process included the removal of the cylinder
head, fuel system, crankcase cover, camshaft, pushrods, spark generation assembly, valves, rocker arm
assembly, and carburetor. This report details the procedure, tools used, and the function of each component.

Detailed Overview of Components Removed:

1. Cylinder Head
The cylinder head is a critical component that sits on the top the engine block and seals the combustion
chambers. It houses the intake and exhaust valves, spark plugs, and fuel injectors (in fuel-injected engines).
In the Toyota 2F engine, the cylinder head is made of cast iron, providing durability and heat resistance. The
head also contains passages for coolant and oil to circulate, ensuring proper engine temperature and
lubrication. The combustion chamber is designed to promote efficient air-fuel mixing and combustion.

2. Fuel System
The fuel system in the Toyota 2F engine consists of the carburetor, fuel pump, and fuel lines. The carburetor
is responsible for mixing air and fuel in the correct stoichiometric ratio for combustion. It uses a venturi system
to create a vacuum that draws fuel into the airstream. The fuel pump, typically a mechanical diaphragm pump,
delivers fuel from the tank to the carburetor. The fuel lines transport fuel under low pressure from the tank to
the engine. The system is designed to ensure consistent fuel delivery under varying engine loads and speeds..

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3. Camshaft and Pushrods
The camshaft is a rotating shaft with lobes (cams) that control the opening and closing of the engine's valves.
In the Toyota 2F engine, the camshaft is located in the engine block and is driven by the crankshaft via a
timing gear or chain. As the camshaft rotates, the lobes push against the pushrods, which transfer this motion
to the rocker arms. The rocker arms then actuate the valves. The camshaft's timing is critical to ensure that the
valves open and close at the correct points in the engine cycle.

4. Spark Generation Assembly

The spark generation assembly includes the distributor, spark plugs, and ignition wires. The distributor is
responsible for routing high-voltage electricity from the ignition coil to the correct spark plug at the right time.
It consists of a rotating rotor inside a cap with contacts for each cylinder. The spark plugs are threaded into
the cylinder head and generate a spark to ignite the air-fuel mixture in the combustion chamber. The ignition
wires carry high-voltage electricity from the distributor to the spark plugs. Proper functioning of this assembly
is essential for efficient combustion and engine performance.

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5. Valves and Rocker Arm Assembly
The valves control the flow of air and fuel into the combustion chamber and
the expulsion of exhaust gases. The Toyota 2F engine uses overhead valves
(OHV), meaning the valves are located in the cylinder head and are actuated
by pushrods and rocker arms. The intake valves allow the air-fuel mixture to
enter the combustion chamber, while the exhaust valves let out the burnt
gases. The rocker arms are pivoted levers that transfer motion from the
pushrods to the valves. Valve springs ensure that the valves return to their
closed position after being opened.

6. Carburetor
The carburetor is a mechanical device that mixes air and fuel in the correct
ratio for combustion. In the Toyota 2F engine, the carburetor is a downdraft
type, meaning the air-fuel mixture flows downward into the intake manifold.
It consists of several key components, including the throttle valve, venturi,
float chamber, and jets. The throttle valve controls the amount of air entering
the engine, while the venturi creates a vacuum that draws fuel into the
airstream. The float chamber maintains a constant fuel level, and the jets
regulate the amount of fuel mixed with the air. The carburetor is tuned to
provide the optimal air-fuel mixture for different engine operating conditions.

1. Equipment and Tools

Engine on which to work:

Toyota 2F (6 Cylinder SI Engine)

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Procedure and Tools Used
1. Guarding and Cover Removal
o The engine was securely mounted on a stand to ensure stability during dismantling.
o All external guards, such as the fan shroud, alternator guard, and other protective covers, were
removed using a socket wrench and screwdrivers.
Tools Used: Socket wrench set, screwdrivers, pliers.
Components Removed: Fan shroud, alternator guard, and other external covers.

2. Cylinder Head Removal

o The intake and exhaust manifolds were detached using a socket wrench.
o The cylinder head bolts were loosened in a crisscross pattern to avoid warping the head.
o The cylinder head was carefully lifted off the engine block using a hoist.
Tools Used: Socket wrench, torque wrench, hoist.
Components Removed: Cylinder head, intake and exhaust manifolds.

3. Fuel System Removal

o The fuel lines were disconnected from the carburetor and fuel pump.
o The fuel pump was unbolted from the engine block.
o The carburetor was detached from the intake manifold.
Tools Used: Wrench set, pliers, fuel line disconnect tool.
Components Removed: Fuel pump, fuel lines, carburetor.

4. Camshaft and Pushrod Removal

o The valve cover was removed to expose the rocker arms and pushrods.
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 o The rocker arm assembly was unbolted, and the pushrods were carefully extracted.
o The camshaft was removed by sliding it out of its bearings after removing the timing gear.
Tools Used: Socket wrench, pliers, camshaft puller.
Components Removed: Camshaft, pushrods, rocker arm assembly.

5. Spark Generation Assembly Removal

o The distributor cap was removed by unclipping its retaining clips.
o The spark plug wires were disconnected, and the spark plugs were unscrewed using a spark
plug socket.
o The distributor was unbolted and removed from the engine block.
Tools Used: Spark plug socket, wrench set, screwdriver.
Components Removed: Distributor cap, spark plugs, distributor.

6. Valves and Rocker Arm Assembly Removal

o The valves were accessed after removing the cylinder head.
o A valve spring compressor was used to compress the valve springs, allowing the removal of
the valve retainers and springs.
o The valves were then carefully pulled out of their guides.
Tools Used: Valve spring compressor, pliers, socket wrench.
Components Removed: Valves, valve springs, retainers, rocker arms.

7. Carburetor Removal
o The carburetor was disconnected from the intake manifold and fuel lines.
o The mounting bolts were removed, and the carburetor was lifted off the engine.
Tools Used: Wrench set, screwdriver.
Components Removed: Carburetor.

Safety Precautions:
• Wear proper PPE, including safety goggles, gloves, and hearing protection.
• Ensure proper ventilation to prevent carbon monoxide buildup.
• Keep hands, clothing, and tools away from moving engine parts.
• Store and handle fuel safely, avoiding spills and ignition sources.
• Use an exhaust extraction system to direct emissions away.
• Never open the radiator cap when the engine is hot.