Unit -5

Syllabus: Maintenance: Pollution control, trouble shooting and servicing procedure

overhauling, engine tune up, tools and equipment for repair and overhaul, testing
equipment, pollution control technologies used for petrol and diesel engines, types and
study of catalytic converters, Euro norms 2 & 3 and Bharat Norms - Recent Trends.

Engine overhauling

Overhauling is the process of ensuring efficient operation of an automobile. It includes

internal cleaning, replacement or adjustment of worn out parts. It is necessary to avoid
premature failure of an engine and shorten life of a vehicle.

Generally overhauling is of two types;

a. Top Overhauling Or Decarbonising

b. Major Overhaul

Top Overhaul: Also known as partial overhaul

Generally engine is not removed from the vehicle

• Consists of cleaning of interior of engine, repair or replacement of minor

assemblies and keeping the valves in good condition.
• it includes:
Step 1: Dismantling
o Removing cylinder head, spark plug, valves and water from radiator pipes.
o Removing carbon from cylinder head, valves and pistons
o Checking valve tappet clearance and adjusting it if needed
o Changing the engine oil
o Adjusting carburetor, ignition system timing of the engine and other
accessories

Step 2
Assembling: before assembling all parts are cleaned and oiled thoroughly

Major Overhaul:
Major or complete overhauling is done to make an engine work in good condition when it
is beyond repair by normal rectification of defects.. Generally major overhauling involves
removal of engine from the vehicle.

It includes;
• Top Overhaul
• Removal of piston and connecting rods for checking and repairing or replacing
worn out parts
 • Honing the cylinders
• Filling new pistons and rings
• Scrapping or replacing the bearings of connecting rod and crank shaft if needed
• Checking the valve timings
• Testing and reassembling

Factors that should be considered to decide the type of overhaul:

Top overhaul is needed in case of leaking valves, leakage between cylinders or general
power loss with out any noise.

Major overhaul is necessary if there is high oil consumption, piston rings are leaking, and
there is internal noise in the engine

Engine overhauling (General/Major):

Procedure: For overhauling an engine it is necessary to dissemble the engine by

removing it from the automobile.

1. By opening drain lock, cooling system is drained

2. To avoid short circuit, battery is disconnected at the terminal
3. Remove air cleaner horn from the carburetor and disconnect its choke and throttle
controls
4. Disconnect fuel tank to fuel pump line
5. Remove radiator stay bar, upper and lower radiator hoses
6. Remove fan hub and fan blades.
7. Remove starting motor by removing cables
8. Disconnect ignition primary wire at ignition coil, wires from generator.
9. Disconnect oil pressure and temperature sending wires, exhaust pipe at the
exhaust main fold
10. Disconnect engine ground strap and remove all its supports
11. Remove rocker arm cover, cylinder head and fly wheel housing by removing bolts
12. Pull the engine forward or backward until clutch clears fly wheel housing

Sequence of operations for engine dissembly:

Remove water pump - exhaust manifold – oil filler tube - water outlet fitting – thermostat
– crank shaft pulley – oil pump – crank case ventilation – rocker arm assembly – cylinder
head – oil pan – piston and CR assembly – timing gear – front end plate -= fly wheel
housing – clutch – fly wheel – crank shaft – exhaust valves and spring – cam shaft –
valve tappets
ENGINE TUNING:

This includes readjusting or replacing the parts as required for restoring new engine
performance. This keeps the engine to operate in good mechanical condition. Every unit
of the engine is made to perform at its best after tuning.

Procedure: A typical engine tune includes visual and mechanical checks and also with
instruments

1. Loose the spark plug, start the engine to blow out carbon and dirt, shut of the
engine and remove plugs
2. Check engine compression. If compression ratio is not up to specification
performance engine service to eliminate the trouble.
3. Reinstall spark plug after getting correct compression ratio.
4. Check and adjust or replace distributor cap
5. Inspect rotor. Replace if it is not in good condition
6. Check high tension leads, wires distributor centrifugal advance, vacuum advance.
7. Check distributor contact points, battery charge, water, battery cables, drive belts,
manifold head, control valve, intake manifold, fuel lines, cooling system for leaks,
coolant level, anti freeze protection, accelerator linkage crank case ventilation
8. Clean or replace air filter element check choke valve, carburetor.
9. Joint dwell and ignition timing
10. Check idle speed and mixture specifications
11. Lubrication, lights and horn, head light adjustment
12. Steering system, suspension system including shock absorber, excessive ply in
clutch, brake and suspension system
13. Front wheels and ball joints
14. Tests to find a weak cylinder cranking motor operation, conditions of ignition oil,
condenser air pressure in tyres etc.,
Pollution control technologies used for petrol and diesel engines:

Major systems for controlling pollutants in automobiles

Positive crank case ventilation
Evaporative emission control
Exhaust emission control.

Positive crankcase ventilation:

• This is a system that sends fresh air through the crank case to sweep out blow by
and fuel vapor.
• The air then enters into the engine where the pollutants from crank case have
another chance to burn

Description of typical Positive crankcase ventilation:

(Figure: Crouse And Angling Pg: 449 Fig 35.2)

1. Filtered air from the air cleaner is drawn

through the crank case by intake manifold
vacuum
2. The air picks up the blow by gas or vapors
and carries them to the intake manifold.
3. The vapors then flow through the intake
manifold to the combustion chamber. There
the unburned fuel burns during the normal
combustion
4. A fixed or variable orifice can prevent the
stalling of the engine because of the entry of
too much air into the engine that disturbs a/t ratio during idling
5. The variable orifice allows only a small amount of air through the engine during
idling. As the speed of the engine increases the intake manifold vacuum reduces
opening the valve further

Purge: The action of clearing the trapped fuel

vapor from the canister is called purging.

Evaporative emission control:

(For carbureted engines)
This system is related to the control of evaporative
loss of gasoline vapors from the fuel tank and
carburetor vents to the atmosphere. The purpose is
to burn the trapped fuel vapor (figure N.K. Giri
Page 520 Fig 13.3)
Vapors from the gasoline in the tank and in the carburetor when engine is not running are
routed to the activated carbon or charcoal consists where they are absorbed.
• When the engine is restarted fresh air is drawn through the activated carbon
• The incoming fresh air removes the vapor from the activated carbon and carries
them to the intake manifold for burning in the combustion chamber
• The carburetor float bowl has two vents. One connects to air cleaner and helps to
compensate for a clogged air cleaner, other vents connects to the charcoal canister

Various arrangements may control this vent.

1. Accelerator- pump liver to open the vent when the engine is off.
2. A solenoid to block the vent when the ignition key is on.
3. The canister has vacuum operated vapor vent or purge valve
4. When the engine is running intake manifold vacuum pulls up the purge valve
diaphragm. This shuts off the vapor from canister so little fuel vapor can enter
5. When engine stops a spring opens the valve and fuel vapor freely flows into the
canister.

Evaporative emission control:

(For engines with fuel tank)

The fuel injection system has no bowl. So the system handles only fuel vapor from
the fuel tank. The canister has two connections. One is the hose from the fuel tank.
The other is purge line to the throttle body. Throttle body and port injected engines
use similar systems. Instead of vacuum operated purge valve, an electric purge
control solenoid may be used.
It mounts on canister or in the purge line. The solenoid is normally open . In many
engines the electronic control module ECM controls the purge valve or canister
purge. The ECM opens the purge valve when the engine has reached normal
operating temperature and is running above idle. The ECM bases its action on data
received from the engine speed and coolant temperature sensors. When the ignition
key is ON, the ECM sends a varying voltage pulse or pulse width modulated signal to
the purge solenoid. Maximum purge occurs when the solenoid de energizes and
opens the purge line. This is 0% duty cycle Minimum purge occurs when the
solenoid energizes and closes the purge line. Since canister purge is an output from
the ECM, this scan tool can read the purge duty cycle. The ECM allows canister
purging to occur only after certain conditions are met. This reduces exhaust emissions
and drivability problems.
Fig35.8 Crouse and angling page 451.

Exhaust emission control:

The four ways to reduce pollutants in exhaust gas are;
1. Controlling gasoline quality
2. Controlling air fuel mixture
3. Controlling combustion process
4. Treating the exhaust gas
Stratified charge combustion (Process of controlling combustion process)
Here combustion chamber with pre-combustion chamber is used
Stratified charge means air and fuel are not mixed uniformly in the combustion
chamber
In stratified charge engine the pre-combustion chamber fills with small amount of
rich mixture
The spark plug extends into the rich mixture when combustion starts; the burning
rich mixture comes out of the pre combustion chamber and ignites the lien mixture
Since there is more lien mixture than rich mixture the average mixture is lien
mixture. So more effective combustion is provided reducing the exhaust emission.

EXHAUST GAS RECIRCULATION

The purpose of exhaust gas recirculation is to remove NOx emission by lowering the
combustion temperature as NOx forms when peak combustion temperature exceeds
3500oF
It recirculates an inert exhaust gas back int0o the intake manifold. The cooler exhaust
gas absorbs heat from the combustion process and reduces the temperature
DISCRIPTION AND WORKING
Fig.454 Crouse and angling 35.B

The EGR system includes a passage

between the exhaust manifold inlet
manifold which will be open or close
as per the condition of the EGR valve.
The EGR valve has a spring loaded
diaphragm that forms a vacuum
chamber at the top of the valve. This
chamber is connected to the vacuum
port in throttle body.
When there is no vacuum the spring pushes the diaphragm down keeping the passage
closed so that no exhaust gas recirculates. This condition takes place during idling
when the NOx formation is minimum.
As the throttle valve opens it moves past the vacuum port. The inlet manifold vacuum
acts through the port and pulls up the diaphragm opening the valve. Some exhaust
gas flows through the valve into the intake manifold. At wide open throttle the intake
manifold vacuum is low and EGR valve closes. Because of speed combustion NOx
formation is minimum.

Catalytic converter:
This converts the harmful pollutants in the exhaust gas into harm less gasses. It is
located in the exhaust system and all exhaust gas must flow through it.
A catalytic convertor will have two different catalysts
1. One catalyst treats HC and CO
 2. The other catalyst treats NOx
The catalyst for HC and CO encourages the HC to untie with oxygen to become H2O and
CO2. This type of converter is called oxidizing convertor.
The metals platinum and palladium are used as oxidizing catalysts.
The catalyst for NOx splits it into oxygen and nitrogen by reducing NOx
This is reducing convertor. The metal rhodium is used in this.

Inside the catalytic convertor the exhaust gasses pass over a large surface area coated
with the catalyst. This surface is either a bed of pallets or ceramic honey comb. Vehicles
with catalytic convertor must use unleaded gasoline.
Types of catalytic convertors:
Dual bed catalytic convertor
Three way catalytic convertor
A dual catalytic convertor has two pallet beds one over the other, they are separated by an
air chamber. The upper bed contains catalysts coated with three way catalysts. It not only
reduces NOx but also oxidizes HC and CO. The lower bed serves as a two way catalyst.
It further oxidizes HC and CO. When the engine warms up air from the air pump feeds
into the air chamber separating the bed.