EXPERIMENT-10

OBJECTIVE
Task assigned to group of students to dissemble and
assemble of an Four stroke engine to make it in running
order.

APPARATUS
1. Four-stroke engine (in non-working condition)
2. Engine disassembly tools (wrenches, sockets,
screwdrivers, etc.)
3. Engine assembly tools (torque wrench, gasket scraper,
piston ring compressor, etc.)
4. Safety goggles and gloves
5. Workshop manual or engine repair guide
6. Notebook and pen

THEORY
A four-stroke engine is a common type of internal
combustion engine widely used in various vehicles and
machinery. It operates on the principle of converting
reciprocating motion into rotary motion to generate power.
Understanding the internal components, their functions, and
the proper sequence of assembly is essential for successful
restoration of a non-working engine.
The four-stroke engine consists of several key components,
including the cylinder block, piston, connecting rod,
crankshaft, valves, camshaft, and timing system. Each
component plays a vital role in the engine's operation, with
precise timing and coordination required for efficient
combustion and power generation.
The four-stroke cycle consists of intake, compression,
power, and exhaust strokes. During the intake stroke, the
piston moves downward, drawing in a fuel-air mixture. The
compression stroke follows, where the piston moves
upward, compressing the mixture. The power stroke occurs
when the compressed mixture is ignited by the spark plug,
driving the piston downward. Finally, the exhaust stroke
expels the burned gases through the open exhaust valves.

PROCEDURE
1. Safety Precautions:
a. Ensure safety goggles and gloves are worn
throughout the experiment.
b. Familiarize yourself with the workshop safety rules
and guidelines.

2. Disassembly:
a. Refer to the workshop manual or engine repair guide
for the proper disassembly sequence.
b. Use the appropriate tools to remove components such
as the cylinder head, crankshaft, pistons, connecting
rods, and camshaft.
 c. Organize and label the removed components to
ensure easy identification during reassembly.
d. Inspect the components for any signs of damage or
wear, noting any necessary repairs or replacements.

3. Cleaning and Inspection:

a. Thoroughly clean the disassembled components
using a suitable solvent and brushes.
b. Inspect the components for any signs of damage,
cracks, or excessive wear.
c. Measure critical dimensions, such as cylinder bore
diameter and piston ring end gap, to determine if they
are within acceptable limits.

4. Reassembly:
a. Follow the workshop manual or engine repair guide
to determine the proper sequence of assembly.
b. Lubricate the necessary components with engine oil
or assembly lubricant before installation.
c. Use the appropriate tools and torque specifications to
tighten bolts, nuts, and fasteners.
d. Pay attention to the proper alignment of timing marks
and the installation of gaskets and seals.

5. Testing and Finalization:

a. Once the engine is fully reassembled, conduct a
thorough inspection of all connections, hoses, and
electrical connections.
b. Ensure all components are properly installed and
tightened.
 c. Conduct a compression test and check for any fluid
leaks.
d. Start the engine and monitor its performance,
listening for any abnormal sounds or vibrations.

POST LAB QUESTIONS

• How does the proper sequence of assembly contribute
to the successful restoration of a four-stroke engine?
• Discuss the importance of referring to a workshop
manual or engine repair guide during the disassembly
and assembly process.
• Describe the role of each component in the four-stroke
engine and how they contribute to the engine's
operation.
• What safety precautions should be taken when
handling engine components and using tools during the
experiment?