First block of projects

Practices 1, 2, 3 and 4.

Course 2023-2024

Made by:

Arnau Barrachina, Roger Magrià, Oscar González and Pol Sendra

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1 Practice 1. Replacement of external elements to the combustion engine. ............. 3

1.1 Description ......................................................................................................... 3

1.2 Objectives .......................................................................................................... 3

1.3 Engine/Vehicle condition ................................................................................... 3

1.4 Disassembly ....................................................................................................... 3

1.5 Invoice ................................................................................................................ 4

1.6 Technical conclusions ........................................................................................ 5

1.7 Operational conclusions .................................................................................... 5

2 Practice 2. Making a Timing Belt ............................................................................... 6

2.1 Description ......................................................................................................... 6

2.2 Objectives .......................................................................................................... 6

2.3 Engine condition ................................................................................................ 7

2.4 Development ..................................................................................................... 7

2.4.1 Before disassembling the timing belt: ........................................................ 8

2.5 Invoice ................................................................................................................ 9

2.6 Technical conclusions ...................................................................................... 10

2.7 Operational conclusions .................................................................................. 10

3 Practice 3: Disassembling, verifying and assembling. ............................................. 11

3.1 Description ....................................................................................................... 11

3.2 Objectives ........................................................................................................ 11

3.3 Element condition, engine, vehicle ................................................................. 11

3.4 Development ................................................................................................... 12

3.5 Invoice .............................................................................................................. 16

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1. Practice 1. Replacement of external elements

to the combustion engine.
Description
In this practice we are meant to disassemble all the external elements mounted on an
Internal Combustion Engine, and so that we get familiar with all the elements that help
the engine run smoothly and give comfort to the occupants in the car.

Objectives
Be familiar with all the components, and all the tools we will need. Understand each
elements function.

Engine/Vehicle condition
The engine we got is a 1.25L petrol engine coming from a 1998 Ford Fiesta. The engine
code is DHC. The overall condition of the engine is correct coming into account the
years of use. The only thing that is broken is the auxiliary belt tensioner

Disassembly
The first thing we need to do is to check the OEM manual in order to get the extraction
process and the mounting scheme.

Auixiliary belt scheme

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Once we got this, we can start stripping down the engine.

The first thing to dismount is the auxiliar belt tensioner which with a 10mm socket we
can loosen the bolt that holds it in place.

Once the tensioner is out the belt can come off.

Now the first element we will be dismounting is the alternator, the A/C compressor
and the steering pump by removing the mount that is held by three bolts to the engine
block. With a 15mm socket we can remove those three elements.

The next step is to remove the intake manifold which is held by six 8mm socket bolts.
When all the bolts are loosen the manifold comes straight out. The next and final step
is to remove the exhaust manifold. By removing three 12mm socket bolts and three
16mm socket nuts the exhaust manifold comes out easy. The assembly process is the
same but in the reverse order

Invoice

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Technical conclusions
Make a technical assessment of the practice, using the maximum technical vocabulary
possible and putting yourself in the place of a specialist mechanic who exposes and
justifies the work carried out to his workshop manager or client.

Operational conclusions
This practice was useful to get to know the working elements mounted on an engine. It
was a great exercise to become more familiar with our tools.

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2. Practice 2. Making a Timing Belt

Description
In this practice we’re going to remove and check the timing belt and all its
components, like the tensioners, and in this case, the camshafts and the
crankshaft. Luckily for us, in this engine the timing moves few elements.

We had some setbacks, but consulting the workshop manual we can solve the
problems and fix them.

Objectives
As an objective, we want to understand how we can disassemble this important
part of the engine. It is a common practice in a workshop, and if we fail, we can
break the customer’s car. Later we will see all the steps to follow for work on a
distribution. That is the main objective of all the group members.

Being the first class working with coworkers, we want to know each other and
learn how to work in groups.

Here we can see the objectives proposed by teachers for this practice:

- Ability to express themselves in writing in work environments.

- Search for technical information on an engine.

- Search and identification of the elements that make up the distribution.

- Understanding of the importance of the timing of the distribution.

- Discriminate with criteria if an element is in good or bad condition.

- Know the current prices of labour and elements related to the distribution of
an engine.

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Engine condition
First, we look for the engine code, and its workshop manual to be able to start
working.

We do and a fast visually inspection of the elements that we’re going to work on,
and we see that some screws are missing, but it doesn't seem like anything is going
to stop us to do our practice (On the top we see one example).

At the end of the practice, we left the car better than it was. Later we will explain
why.

Development
Technical data about the engine:

- Code: “DPC F43800” (Volkswagen Golf VIII 1.5 TSI)

- Distribution scheme:

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Torques of some elements

- Crankshaft belt: Phase 1: 150 Nm, Phase 2: 180º
- Camshaft sprocket (exhaust side): Phase 1: 50 Nm, Phase 2: 135º
- Camshaft sprocket (intake side): Phase 1:

Specific tools that we are going to use:

- Torque wrench

- Angle meter

- Twelve-pointed socket

- Impact gun (because we don’t have the distribution draft tool)

Before disassembling the timing belt:

Before start working, we take a look to all the elements of the timing belt and we see
that the camshafts were poorly assembled, so we dismounted for put it on marks.
After, we disassembled the crankshaft pulley, which cost us a little because of how
tight the screws were.

Once everything was disassembled, we put the engine on marks as indicated by the
manufacturer. To do it, we put the crankshaft with the piston 1 on TDC and we use the
special tool for it, like this image:

After, to align the camshafts on the marks we had to remove the camshaft’s pulleys
and turning them, like the next image.

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Once placed like this, we were able to tighten the pulleys to the corresponding
tightening torque. Now we just have to put the belt on and tighten the automatic
tensor.

Invoice

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Technical conclusions
Changing the timing belt is a process that is not complicated, but it does require a lot
of precision and using the necessary tools correctly.

In this case, we have found that the engine had certain defects, such as a poor
adjustment of the camshafts, or a broken screw in the distribution cover as we see in
the following photo.

We have been able to put everything exactly as the manufacturer indicates. In a real
case, we would only need to change some of the elements that we have manipulated,
such as the belt, the tensioner and the pulleys, which is what the manufacturer says.

Operational conclusions
We enjoyed doing the practice since we had all the necessary tools and the process
was not complicated for us. There are three of us in middle school and one in high
school, and he has learned a lot. Together we have helped you understand how the
elements work among many tips.

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3. Practice 3: Disassembling, verifying and

assembling.
Description
After this practice, we will identify and become familiar with the key elements that
make up the cylinder closure. At the same time, we will be able to see first-hand the
purpose of the cylinder head. During the session, the timing disassembly procedure
will have to be followed, so we can be mounted properly and the engine can rotate
in a correct way, in order to continue disassembling the various components which
will be checked outside the vehicle. Finally, the entire system will be reassembled
and restored once it has been analyzed.

Objectives
-Search technical information about the engine.

-Develop the ability to express oneself in writing in work environments.

-Identify the elements that make up the system/set to be analyzed.

-Understand the functions of the tested elements.

-Associate the fixing elements with the necessary tools.

-Determine with criteria if an element is in good or bad condition.

-Know the current prices of labor and elements of a cylinder head.

Element condition, engine, vehicle

There were some missing screws of the pulley, the tensor, in the oil sump, and in more
elements, also the tensor was broken, so that took us a long time of the practice to
take it out, repair it and then mounted in the correct way. Also the glow plug was
deformed by an overheating process

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When we finish the engine, there were the exact number of screws as at the
beginning, we put it on marks, because the timing wasn’t mounted properly, we fix the
tensor and we were able to make the engine rotate two times.

Development
Consult technical data on the engine. (CFHD) the engine is from an AUDI A1 (8X) 2.0
TDI 2012.

It involves the following jobs:

For the dismounting process, we had to check the workshop data, and make use of the
especial equipment of the group VAG, we put it on marks so we can remove the
camshaft and be able of taking out the cylinder head. The special tools were the next
ones:

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After put it on marks, we lock both the crankshaft and the camshaft, also we tried to
took off the tensor as the brand says, but due to it was broken we had to do it with a
mallet and praying with a power bar, and we did it. After the disassembling process,
we verified the flatness, with a straightedge and the feeler gauges. After all of that we
mounted perfectly and check if it turns two times.

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The torques were the next ones:

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Invoice

6. Technical conclusions
In this practice basically we had to make the dismounting process of the cylinder
head, for doing that we had to check the manual to set and order of the process.
Firstly, we took of all the covers that have no function to see clearly the engine block
and check if we could do it with out taking the timing belt. After checked that we
can’t we set the engine in marks, but due to it wasn’t mounted correct previously,

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we had to put the camshaft and the crankshaft in the correct way, after that we
dismounted the camshaft and took of the cylinder head so we can measure the
flatness with a straightedge and the feeler gauges and was good so we wouldn’t had
to have send the piston head to rectification, to sum up, the state of the engine was
good so we wouldn’t have to change any big part of the engine.

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4. Practice 4: Cylinder head and all its elements.

Description
In the following practice, the student will learn how to check the condition of a
cylinder head and its elements. To do this, the cylinder head will be completely
isolated, disassembling any part that it houses. Once this is done, a series of
measurements will be taken using various measurement tools such as the vernier
caliper, the alexometer, the micrometer, etc. After taking all the measurements, they
will be recorded in the Excel table of cylinder head measurements provided for this
purpose, this will allow later diagnosis of the condition of the verified system.

Objectives
-Search technical information about an engine.

-Ability to express oneself in writing in work environments.

-Identification of the elements that make up the set to be analysed.

-Understanding the functions of the tested elements.

-Association of the fixing elements with the necessary tools.

-Discriminate with criteria if an element is in good or bad condition.

-Know the current prices of labor and elements of a cylinder head.

Element condition, engine, vehicle

The engine seems to be a little worn but in good condition. For example, the camshafts
looked new, but some parts such as the water pump were poorly tightened by the
previous group, apart from a few things, everything was fine.

Development

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4.1. Equip yourself with the Personal Protection Equipment (PPE)

To do this practical assignment we used security boots, mechanic gloves, and work
clothes.

4.2. Consult technical data on the engine. Engine code, vehicles and engines where it
is mounted (Rely on Workshop Manuals, Workshop Data, Internet...)

Looking at the engine, we found the code “Z10XE”, which correlates with an Opel
Corsa C (X01) 1.0 12V 2001-2006.

4.3. Identify the elements of the cylinder head assembly, its elements and systems.

The elements are the cylinder head, camshaft, valves, springs, combustion chambers,
valve seats, collets and oil pressure sensor.

4.4. Disassemble and/or verify element by element. (take photographs to include in the
report and to be used as a guide during assembly later).

In this practice, the following verifications must be carried out:

CYLINDER HEAD

-The volume of the combustion chamber.

We used water to measure the volume of the combustion chamber, for this purpose
we used a methacrylate plate with two holes, in one of them we inject the water with
a burette and with the other we allow the air to exit.

With a well calibrated burette we can find out how much water we used.

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The result is 29 mm³, which is the quantity that fits in the combustion chamber.

-Valve guide condition and play.

The valves are not in bad shape, just a little bit dirty.

VALVES

-Head and stem diameter measurements (valve condition)

With the measurements made with a micrometer we know the intake valve face
diameter is 27,95 mm and the exhaust valve face diameter is 24,98 mm.

The valve steam diameter is 4,97 mm.

- Grinding the valves (1 or 2 each depending on available time)

We grinded the valves with the grinding paste, we put the paste surrounding the valve
and we proceeded to grind it with a suction cup.

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-Length of the spring and thickness of the coil (confirm with OEM specs)

With a caliper we measured that the spring length is 40,30mm.

4.5. Analyze the state of the components.

The oil pressure sensor is broken, and a collet is missing in one of the valves, a little
dirt aside, everything else is correct.

Invoice
Make the budget for this practice taking into account the time spent and the hourly
price indicated by the workshop guild.

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Technical conclusions
We started by dissembling the cylinder head to access the valves, then we took said
valves off and changed the collets because there were some missing. We measured
the diameters of the valves with the multimeter.

Operational conclusions
At first, we had time but because of some complications, we ended up with a tight
schedule to finish the practice, that taught us how to work under pressure and finding
solutions to things that we couldn’t understand at the beginning. This was thanks to
team work.

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