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SWAMI KESHVANAND INSTITUTE OF TECHNOLOGY MANAGEMENT & GRAMOTHAN, JAIPUR

Automobile Engineering Lab


Experiment No.1

Experiment:To study
I. II. III. Types of Valves in an Automobile The purpose of valve re- facing, valve seat grinding Leakage of valve, and checking of leakage.

Objective:After study of the above valve system, a student would: 1) Be able to know different types of valves used in automobiles. 2) Will be acquainted with the process of valve refacing and valve regrinding and need of these. 3) Able to diagnosis various defects developed in valve systems and the methods to rectify these defects.
EQUIPMENT USED:-

1. Poppet valves 2. Valve refacer machine 3. Cylinder head 4. Valve seat grinder 5. Grinding mixture

6. Cylinder pressure tester 7. A set of fix spanners and ring spanners

TheoryValves are the devices, which are used for regulating the flow of fluids or liquids inside the cylinder. Automotive valves of various types and of varied sizes and dimensions are used in almost all types of cars, trucks, aircraft, two wheelers and tractors. Worldwide automotive valves suppliers are offering a wide variety of auto valves in different materials. Auto valve used in automobiles can be made from a variety of raw materials like stainless steel, brass, copper, galvanized iron, carbon steel, caste steel, aluminum, and bronze. In an Automobile of four stroke engines, two valves namely intake and exhaust auto valves, are used for letting air and fuel mixture in and burnt fuel out from the engine cylinder. Auto valve is a device used for controlling and regulating the flow of air/ fuel mixture. The picture of a valve poppet type generally used in an automobile is given below.

POPPET VALVE The diameter of the inlet valve face is larger than the diameter of the exhaust valve face. It is on account of reason to allow maximum air fuel mixture inside the cylinder in least possible time.

Valve Refacing:-

On account of continuous use of valves as inlet as well as exhaust valve, the surface finish of the face of the valve gets distorted. As a result, valve does not fit properly on the valve seat. Therefore, there may be leakage between the valve and valve seat. On account of this leakage there is a pressure drop inside the cylinder of an engine, as such the efficiency of the engine goes down. On account of the leakage, there may not be full combustion of the fuel and the unburnt fuel may also leak out through the exhaust valve. Therefore fuel average also drops. Some times on account of high temperature a portion of exhaust valve and exhaust seat also burns out. Therefore valve refacing and valve seat grinding is required for proper surfaces of the valve faces and the valve seat,to make the valve properly seated on the valve seat. This has to be leak proof. PROCESS OF VALVE REFACING:A valve refacing equipment/machine is used for refacing the face of the valve. The angle of the face has to be 45 degree. Figure of the valve refacing machine generally used is given below

VALVE SEAT GRINDING:The surface of the valve seat is also grinded by hand valve grinders or electrically operated grinders. After finish the angle of the seat has also to be 45 degree, to match the valve face angle for proper seating to make them leak proof.

Types of valve Troubles:I. II. III. IV. V. Valve sticking Valve burning Valve breakage Valve face wear Carbon deposits on valve face

Leakage of Valves:Leakage of valves takes place on account of the following reasons:1. Improper seating of the valves- Valves are manufactured with a face angle of 45 and valve seats with an angle of 45 or 46, so that there is proper seating of valves and seats. 2. Valve face wear, valve face burning, seats damage or burning- In all these cases improper seating, thereby leakage of gases. 3. Sticking of valves inside the guides will not allow the valves to seat freely thereby causing leakage. Sticking of the rocker arm can also cause valve remaining open.

Checking of Valve leakage:Checking of valve leakage is done with the help of a pressure testing gauge. Spark plug or injector is opened one by one, pressure testing gauge is put inside the cylinder and properly seated in the hole (spark plug), the engine is cranked, then the pressure in each cylinder is noted. In a four cylinder engine if the1. Pressure in one cylinder is less and pressure is proper in rest of the three cylinders, then it indicates valve leakage. 2. If the pressure in two successive cylinders is less, then it indicates cylinder block head gasket leakage. GRINDING THE VALVE FACESwitch on the workhead and wheelhead motors and bring valve to center of gri ndi ng wheel. Feed the wheel slowly i nt o thevalve, taking a very light cut. Move work table back andforthwith short strokes using full face of wheel but always keepingvalve on wheel.To makeinspection or when finished grinding,back wheelhead away from valve, not valve off wheel. Thisgrinding method adheres to accepted shop practice with precision industrial grinders for large production, and appliesequally well to valve refacing for maintenance. Use rack to keepvalves in same order as removed from block and be sure toreturn each valve to its own guide. Always lubricate valvestem with light o i l before returning to guide. Oilis available for dressing the grinding wheel and grinding the valve face byt urning the coolant control indicator toward that wheel. Thespeed of the coolant is regulated by the

angular movement ofthe control. Coolant is avaiable for the attachment end by turning the control indicator in that direction.

VALVE SEAT GRINDING:warning w e a r protective cl ot hi ng and go ggl e s whi le grindi ng to p r e v e n t per so na l i n j u r y f r o m fl yi ng particles.

The Val ve Seat Grinding Stone gives an accurate, mirror-smooth face on ever y job. Lapping v al v e s in their seats is unnecessary if precision equipment is correctly used a n d v a l v e seat a n d v a l v e face test true with Prussian Blue or a Val ve Seat Indicator.

TESTING FOR VALVE LEAKAGE 1) Open a spark plug one by one from the cylinder block. Insert in the spark plug hole, a pressure testing gauge. 2) Crank the engine. 3) If there is a less pressure in one cylinder, then it indicates valve leakage. 4) If there is a drop of pressure in two consecutive cylinders, then it indicates leakage of gasket. 5) If there is a valve leakage, open the cylinder head, remove valve, reface it and gring the valve seat and refit it. Check it again. 6) There would not be any pressure drop in any cylinder, which indicates there is no leakage of valves or gasket.

FAULT DAIGNOSIS: 1) VALVE LEAKAGE: - Indication drop of pressure in one cylinder. - Vehicle will not picks up speed and more consumption of fuel. 2) VALVE STICKING: - Check the spring and the valve guide. 3) VALVE TIMING NOT CORRECT: Vehicle will not pick up speed and check valve timing

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