Automotive Mechanics

Level-III

Overhaul refers to an examination of machinery and

the repairs or changes that are made in response to
the condition of the system. Interchangeable with
Maintenance Repair and Overhaul (MRO) and Tear
Down, Overhauling machinery can be unavoidable, and
the only process that can restore machinery to working
condition.
An engine is some machine that converts energy from a fuel to some
mechanical energy, creating motion in the process. The engine is
known as the heart of the vehicle. During the engine operation, it
generates extreme heat. Therefore, engine parts need to bear extreme
heat and wear and tear due to that they may damage over time. As the
 1. Basic Engine Components
A. Cylinder head

Engine head is casted in the same way as engine block. Its mold is made such that the
casted piece must have an opening for air to flow into engine cylinder and an exhaust
opening from where the burnt gases will go out.

A.Valves
As we have already know that they control the inlet and exhaust air to go into and out of
engine cylinder. Valve is mounted upside down means valve head is facing engine
cylinder.
 Camshaft
The camshaft is a mechanical component of an
internal combustion engine. It opens and closes the
inlet and exhaust valves of the engine at the right
time, with the exact stroke and in a precisely
defined sequence.
Crankshaft
A crankshaft is a mechanical component used in a
piston engine to convert the reciprocating motion into
rotational motion. The crankshaft is a rotating shaft
containing one or more crankpins, that are driven by
the pistons via the connecting rods. Crankshaft (red),
pistons (gray), cylinders (blue) and flywheel (black)

Crankshaft Casing or Oil Sump

The oil pan is a large part of the crankcase

within a wet sump engine. Here, oil is stored
and used to lubricate parts of the engine.
 Engine Block
Engine Blocks (sometimes called Cylinder Blocks) are the large casings
that contain the Cylinder and its internal components, intake and
exhaust passages, coolant passages, crankcases, and other internal
components.
Piston
In an engine, its purpose is to transfer force from expanding gas in the
cylinder to the crankshaft via a piston rod and/or connecting rod. In a
pump, the function is reversed and force is transferred from the
crankshaft to the piston for the purpose of compressing or ejecting the
fluid in the cylinder.
A.Connecting Rod
It is an ‘I’ shape structure whose one end is connected to piston and other one to
crankshaft. The piston side end of connecting rod has hole in it. And we have also got a
hole in piston’s cylindrical structure just beneath the piston rings.
The overhaul process involves taking the engine apart and diligently
identifying faulty components. Once everything is replaced and
cleaned, a professional will rebuild the engine. An overhaul can help
improve the performance and power of a diesel machine.
An engine overhaul is a process of removing, stripping, checkup, cleaning,
and repairing the faulty internal parts of the engine. In the overhauling
process, the technician removes the engine parts and then inspects the parts
to find the problem. For example, if your engine piston, head gasket,
camshaft, crankshaft, connecting rod, or bearing has been damaged, the
technician repairs it.
An overhaul is a service that returns an engine to
like-new condition. During the overhaul process,
engines are removed from equipment, completely
disassembled, fully inspected and cleaned, repaired
in places where repairs are needed, then tested for
performance.
 1. Symptom of Engine Fault
One or more of the below-given common symptoms indicate that your engine overhaul
is need an engine overhaul.
A.White Exhaust Smoke

As the engine oil or coolant enters the cylinder, it mixes and burns with the air-fuel
mixture; due to that, engine emits white smoke from the vehicle tailpipe. This white
smoke indicates that vehicle has a damaged gasket or piston ring. As continuously
observe the white smoke, drive vehicle to a mechanic and ask for an engine overhaul.
However, do not confuse it with the white smoke that the vehicle emits at the initial
start-up.
 B. High Oil Consumption

One of the major signs car engine requires an overhaul is extreme oil consumption. If
the engine oil level goes down very quickly or the low oil pressure warning light
comes on, it means engine has a leaky or damaged part. A damaged head gasket, a
damaged hose, or a damaged piston ring can cause a quick reduction in the engine oil
level.
C. Black Exhaust Smoke
The engine emits black smoke due to carbon deposits on the intake valve and
piston. Constant emission of black smoke usually indicates that the engine needs
an overhaul. It generates problems in air-fuel mixture combustion. As a result,
engine performance and fuel efficiency are reduced.
 D. Reduction in Engine Performance

Engine misfiring issues occur when the air/fuel ratio in the engine cylinders is
incorrect or when the spark plug doesn’t properly ignite the air/fuel mixture. The
engine misfiring reduces the acceleration of the vehicle and reduces engine
performance. If the cause of the problem is a worn spark plug, it can be easily
replaced.
E. Engine Overheating

Engine overheating means cooling system is not working properly. The engine most
commonly overheats due to a faulty water pump, leaky hoses, insufficient engine oil,
insufficient coolant, a damaged combustion chamber, or a leaky radiator. It may also cause
due to leaky head gaskets.
F. Coolant Level

A quick reduction in the coolant level is a clear sign that your engine has a leaky part
and it needs an overhaul. The leaky head gasket, damaged piston ring, or cracked
engine cylinder may lead to a quick reduction of the coolant level.
 G. Strange Noises from the Engine

A strange engine noise usually means that your engine has a broken, cracked, loose, or
worn part. The knocking noise may represent that there is excessive clearance between
the piston rod and the crankshaft or that there is a problem with the valve train. This
unpleasant noise may also cause due to a damaged piston ring.
H. Check Engine Light

The latest vehicle models contain a check engine light. When something goes bad with
your engine, the check engine light starts to illuminate. This warning light may also
indicate a severe engine issue. A faulty spark plug, a damaged fuel injector, a low coolant
level, insufficient engine oil, a damaged engine cylinder, or a faulty engine sensor are the
most common causes of the check engine light illumination.
 I Oil Sludge

The oil sludge on the fuel cap or dipstick is one of the clear signs of an engine issue.
The oil sludge may accumulate due to one or more of the following causes:
o Coolants
o Wrong engine oil
o Old engine
o Grime
The oil sludge accumulation shows that the parts of your engine are not lubricated
properly.
 J. Compression test

Compression loss is a situation commonly associated with reduced performance

and a decrease in power. An engine coolant or fuel leak may lead to engine oil
contamination, leading to a higher oil level in the crankcase.
However, the compression loss often suggests leaks occurring elsewhere within
the engine as well. An engine cylinder is usually leaked due to excessively worn
components that require replacement. Deteriorating performance and a leaking
engine cylinder signal that an overhaul is necessary.
 K. Dropped Valve

A dropped valve takes place if the valve head of the vehicle engine becomes bent and
severed, leading it to fall into the engine cylinder. This event can inflict significant damage
on the whole engine.

1. Engine cleaning
Automobile engines attract and accumulate particles during its operation and these
deposits could come in these forms: - water soluble deposits, organic soil, rust or scale.
Effectively cleaning these deposits require the use of the most appropriate cleaning
method, bearing in mind that cleaning takes a very significant part of the running budget
of an automobile workshop.
  Types of Contaminants
Being able to recognize the type of dirt you are to clean will save you time and effort.
Basically there are four three types of dirt.

1. Water-Soluble Soils
The easiest dirt to clean is water-soluble soils, which includes dirt, dust, and mud.
Organic Soils Organic soils contain carbon and cannot be effectively removed with plain
water.
2. Organic Soils

Organic soils contain carbon and cannot be effectively removed with plain water.

3 .Rust
Rust is the result of a chemical reaction that takes place when iron and steel are exposed
to oxygen and moisture. Corrosion, like rust, results from a similar chemical reaction
between oxygen and metal containing aluminum. If left unchecked, both rust and
corrosion can physically destroy metal parts quite rapidly.
4. Scale
When water containing mineral and deposits is heated, suspended minerals and
impurities tend to dissolve, settle out, and attach to the surrounding hot metal
surfaces. This buildup of minerals and deposits inside the cooling system is known
as scale. Over a period of time, scale can accumulate to the extent that passages
become blocked, cooling efficiency is compromised, and metal parts start to
deteriorate. 1. Methods OF Engine Cleaning

There are three basic processes for cleaning automotive engine parts. The first process that is
discussed is chemical cleaning. This method of cleaning uses chemical action to remove dirt,
grease, scale, paint, and/or rust. Unfortunately, the most traditional line of defense against soils
involves the use of cleaning chemicals. Chlorinated hydrocarbons and mineral spirits may have
some health risks associated with their use through skin exposure and inhalation of vapors.
Hydrocarbon cleaning solvents are also flammable. The use of water-based nontoxic chemicals
can eliminate such risks.
 •Chemical Cleaning Machines
•Parts Washers

Parts washers (often called solvent tanks) are one of the most widely used and inexpensive
methods of removing grease, oil, and dirt from the metal surfaces of a seemingly infinite variety of
automotive components and engine parts. A typical washer setup might consist of a tank to hold a
given volume of solvent cleaner and some method of applying the solvent. These methods include
soaking, soaking and agitation, solvent streams, and spray gun applicators.
Figure 1.13 Chemical Cleaning Machines

Soak Tanks
There are two types of soak tanks: cold and hot.
 Cold Soak
Tanks are commonly used to clean carburetors, throttle bodies, and aluminum parts. A
typical cold soak unit consists of a tank to hold the cleaner and a basket to hold the
parts to be cleaned.
After soaking with or without gentle agitation is complete, the parts are removed,
flushed with water, and blown dry with compressed air.

 Hot soak
tanks are actually heated cold tanks. The source of heat is electricity, natural gas, or
propane.
The solution inside the hot tanks usually ranges from 71°C to 93°C. Most tanks are
generally large enough to hold an entire engine block and its related parts. Hot tanks use
a simple immersion process that relies on a heated chemical to lift the grease and grime
off the surface. Liquid or parts agitation may also be used to speed up the job.
 Hot Spray Tanks
The hot spray tank works like a large automatic dishwasher and removes organic and
rust soils from a variety of automotive parts. As with the hot soak method, spray washers
soak the parts, but they also have the benefit of moderate pressure cleaning. Using a hot
jet spray washer can cut cleaning time to less than 10 minutes. Normally, a strong soap
solution is used as the cleaning agent. The speed of this system, along with lower
operating costs, makes it popular with many Spray washers are often used to pre-clean
engine parts prior to disassembly.
Thermal Cleaning
The second basic process for cleaning engine parts
is thermal cleaning. This process relies on heat to
bake off or oxidize dirt and other contaminants.
Thermal cleaning ovens, especially the paralytic
type, have become increasingly popular. The main
advantage of thermal cleaning is a total reduction
of all oils and grease on and in blocks, heads, and
other parts.
Abrasive Cleaners
The third process used to clean engine parts involves the
use of abrasives. Most abrasive cleaning machines are
used in conjunction with other cleaning processes rather
than as a primary cleaning process itself.

 Cleaning by Hand

Heavy buildups of grease and/or carbon should

initially be removed by scraping or wire brushing.
Cleaning aluminum and other soft metals with
either technique should be done with extreme
care, especially while using a steel scraper or
brush. Steel or plastic scrapers are used to
remove old gasket material from a surface and
heavy sludge.
Power tools with a small sanding disc (normally
emery cloth) are available.
Abrasive Blaster
Compressed air shot and grit blasters are best used on parts that will be machined after
they have been cleaned. Two basic types of media are available: shot and grit. Shot is
round; grit is angular in shape. Parts must be dry and grease-free when they go into an
abrasive blast machine.
Otherwise, the shot or beads will stick. Steel shot and glass beads are used for cleaning
and/or penning the part’s surfaces. Penning is a process of hammering on the surface.
Parts Tumbler
A cleaning alternative that can save considerable labor when cleaning small parts
such as engine valves is a tumbler. Various cleaning media can be used in a tumbler to
scrub the parts clean. This saves considerable hand labor and eliminates dust. In
some tumblers, all parts are rotated and tilted at the same time.

Vibratory Cleaning
Shakers, as they are frequently called, use a
vibrating tub filled with ceramic, steel, porcelain,
or aluminum abrasive to scrub parts clean. Most
shakers flush the tub with solvent to help loosen
and flush away the dirt and grime. The solvent
drains out the bottom and is filtered to remove
the sludge.
 Alternative Cleaning Methods

Three of the most popular alternatives to traditional chemical cleaning systems are
ultrasonic cleaning, citrus chemicals, and salt baths.