TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List Abbreviations x
CHAPTER 1: INTRODUCTION 1
1.1 BACKGROUND OF STUDY
1 1.2
PROBLEM STATEMENT 1
1.3 PROJECT OBJECTIVES
2 1.4
WORK SCOPE 2
CHAPTER 2: LITERATURE REVIEW 7
2.0 THEHISTORY OF AUTOMOTIVE ENGINE
3 2.1
THE CONCEPT OF THE 4 STROKE ENGINE 3
2.2 THE TYPE OF FUEL INJECTION SYSTEMS
4 2.3
THE BASIC ENGINE PARTS 5
2.4 ENGINE MECHANICAL DIAGNOSIS
9 2.4.1
DIAGNOSING EXCESSIVE OIL COMSUMPTION 2.4.2
DIAGNOSING OIL PRESSURE PROBLEMS 10
2.4.2.1 CHANGE OILTEAT PRESSURE
11 2.5
THE CHASSIS DYNAMOMETER 12
2.6 ENGINE MAINTANCE
13 2.6.1
ENGINE OIL 13
2.6.1.1 SELECTION OF OIL
14 2.6.2
ENGINE COOLANT 14
v
2.6.3 BATTERY
14 2.6.3.1
CHECKING BATTERY LEVEL 14
2.6.3.2 DISCONNECTION AND CONNECTION
15 2.6.4
BRAKE FLUID 15
2.6.5 POWER STEERING FLUID
15 2.6.6
CLUTCH FLUID 16
2.6.7 FORM-INIPLACE GASKET
16 2.6.7.1
DISASSEMBLY 16
2.6.7.2 SURFACE PREPARATION
16 2.6.7.3
FIPG APPLICATION 17
2.7 INSPECTION OF THE ENGINE PARTS FOR 4G15 ENGINE
17 2.7.1
TIMING BELT 17
2.7.2 AUTO-TENSIONER PULLEY
17 2.7.3
ROCKER ARM AND CAMSHAFT 18
2.7.4 CYLINDER HEAD AND VALVES
18 2.7.4.1
CYLINDER HEAD 18
2.7.4.2 VALVES
18 2.7.5
OIL PAN AND OIL PUMP 19
2.7.5.1 COUNTER BALANCER SHAFTS
19 2.7.5.2
OIL PUMP 19
2.7.6 CRANKSHAFT AND CYLINDER BLOCK
19 2.7.6.1
CRANKSHAFT 19
2.7.6.2 CYLINDER BLOCK
20 2.7.6.3
BORING CYLINDER 20
2.7.7 PISTON AND CONNECTING ROD
22 2.7.7.1
PISTON RINGS 22
CHAPTER 3: METHODOLOGY 25
3.0 FLOW CHART
26 3.1
SPECIFICATION 27
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3.1.1 ENGINE
27 3.1.2
OTHER SPECIFICATION 28
3.2 OVERHAUL METHODOLOGY
29 3.3
THE CHASSIS DYNAMOMETER TESTING 32
3.3.1 PROCEDURE
32 3.3.2
EXPERIMENTAL DATA 33
CHAPTER 4: RESULT DISCUSSION 34
4.1 METHODOLOGY OF OVERHAUL 4G15 ENGINE
34 4.1.1
STAGE 1 REMOVE THE ENGINE FROM CAR BODY 34
4.1.2 STAGE 2 DISASSEMBLE THE ENGINE PARTS
40 4.1.3
STAGE 3 INSTALLATION THE ENGINE PARTS 46
4.2 VERIFICATION THE SPECIFICATION OF THE 4G15 ENGINE
52 PARTS
4.2.1 REBORE THE ENGINE CYLINDER BLOCK
52 4.2.2
ADJUSTING VALVE CLEARANCE 54
4.2.3 REFACE THE ENGINE HEAD SURFACE
55 4.3
DISCUSSION 57
CHAPTER 5: CONCLUSION FUTURE WORK 59
