Overhauling 4G15 Internal Combustion Engine

I have an experienced in overhauling an internal combustion engines, the type of engines that i had overhauled was 4G15 engine of Proton Wira sedan, with 1.5 cc and inline-4 piston orientation. All the procedures to overhauled the engines has been learned by me and I now can guaranteed that i can managed to troubleshoot that types of engines if problems arise. The video of my work can be seen below:

let me tell you some of the procedures to overhauled the 4G15 engines as i carried out before. This is the procedures for the piston, piston rings,bearings, oil pump and the connecting rod.

PISTON REMOVAL.

1.     Firstly, the nuts for the connecting rod cap on the number one piston was being removed. The rod cap          was hitted gently in order to remove the piston. The bearing at the rod cap was also being removed.

2. When all the pistons had been removed, it been put in a separate place in order to maintain the piston           from any scratches or damage. The piston had been labelled correctly prior to its positions in cylinder           blocks.

3. The piston and its other components was kept in its original form in order to make things easier and to           avoid losing the components such as crank pin and the bolts.

PISTON INSTALLATION.

1. First thing we did to install the piston back inside the cylinder block was installing the rod bearings of the piston.
   
   
2. After the rod bearing being installed, the piston ready to be putted inside the cylinder blocks, so, we used the piston ring compressor in order to aided the piston into the blocks. The grip of this tools on the piston was set not too tight and not too loose in order to make it easier to be remove after the piston was ready to be placed in the blocks.
   Position piston in cylinder
   
   
3. The mallet was used to hit the piston in to the cylinder blocks. The edge of the piston ring compressor was being hit gently in order to make sure that is no gaps between the blocks and the compressor, as the piston ring will stucks between the gaps during the hitting of piston inside the blocks if not properly manage. Then the head of the piston was being hit fast enough by the back of the mallets to insert it into the blocks.
   
   
4. After the piston had been matched with their position to the crankshafts, we installed the rod caps.
   
   
5. After all had been finished, the bolts then being put to the rods and to fasten it, torque wrench had been used as the bolts need the same torque when being fastened to be balance. The torque was started by using 20Nm of torque first, then goes up to 40Nm, and at last, 50Nm, in a zig zag movement.
   
   

INSPECTION

1. Preparation for piston installing
   
   
2. Installation of wrist pins
   
   
3. Installation of rod bearings
   
   
4. Installation of pistons
   
   
5. Torque the rod bolts
   
   
6. Removing pistons and checking bearing clearance

PISTON RING INSTALLATION

1. Fit new rings in cylinder. Old ring was being replaced in order to get better performance of the engine.
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2. Measure and adjust ring gap.
   
   
3. Cleaning of the ring with water and detergents.
   
   

BEARING.

1. The crankshaft bearing caps had been removed wisely.
   
   
2. The bearings had been removed. Screwdrivers was used to push the bearings.
   
   
3. The bearings that can be use again was kept to be assemble again in the engines.
   
   

CONNECTING ROD INSTALLATION

The connecting rod was installed correctly to their original pistons. This is easier as all the piston components had been labelled correctly and was put altogether with their basic components.

OIL PAN REMOVAL.
Firstly before removing the oil pan, we first empty all the lubrication oil inside it. Then the engines was turned upside down in order to make job easier. After that, all the bolts that joints the oil pan with the blocks was removed by tools. All the bolts was counted and placed in a specific area to avoid of losing it. Then the oil pan was cleaned and all the gaskets pieces was torned by using a scrappers.

OIL PUMP INSTALLATION

1. The oil pump had been installed correctly after all the bolts that join the connecting rod and the crankpin already been torque bolted. The oil pump was been inspected for any damages before installing it.
2. After installation of the oil pump, we then put the oil pan gaskets in its positions, the gasket was precisely made in order to avoid leaking of the lubrication oil when the oil had been putted into the engines. To sticks the oil gaskets onto its positions, we used a special glue in order to make its stay on its position. The hole for the bolts penetration also had been made for the gasket to provide an area for the bolts to be installed.

After oil pan gaskets had been installed, the oil pan then been bolted. 

Preparing Business Proposal to Open a Service Workshop

COMPANY BACKGROUNDS

Unknown enterprise is an auto servicing and repairing cars workshop which will be locate in Taman Sutera Prima, Seberang Jaya, Pulau Pinang. The idea of opening this workshop was to make a reliable business by applying all the skills and experienced so do the information in cars servicing in the automotive world. The lot of opportunities in this business also had brought us to start this workshop as we can see there are increasing numbers of vehicles, especially cars in Malaysia nowadays. So the needs of repairing and servicing the cars had increase as there will be some or a lot of problems experienced by the owner of the car. The solution of the problems was absolutely by going to the workshops and also the service centre. This is what we see to be our opportunity to open cars workshop in order to use our information by repairing the cars that had been sent to our workshop as well as to make profit by starting this business. This company will offered servicing and repairing of all type of car depends on the half-cut that can be get in within the area, exhaust welding, wheel balancing and engine overhaul. Other than that, we also offer experienced mechanics to do all the repairing and services in this workshop. All the mechanics was make sure to have at least 4 years of experienced in the automotive servicing in order to provide five star service to our customers. They also had been interviewed in order to ensure all the qualification had been satisfied. Unknown workshop also provides towing services for the customers whom having problems getting their car to the workshops as for example, their cars facing a problems during travelling on the roads. Unknown enterprise will also supplies auto parts for nearly all types of the cars.

Our workshops will be opened on 12 may 2012 at no 2, Bangunan Lot Kedai Taman Sutera Prima, 13800,Seberang Jaya, Pulau Pinang. Business hour is 10.00 am till 7.00 pm daily, and will be closed on Sunday and Public Holidays. For information and help, all of our customers may be pleased to contact us on 012-2346678 and 019-5654900 or fax us on 608-565 8014.

MISSIONS.

Unknown Enterprise aims to offer high-quality auto repair services and a full range of auto parts. Unknown Enterprise focuses on personalized service and repairing to its customers by offering convenience and rapid service. Additionally, Unknown Enterprise is technologically savvy with computerized monitoring of all parts inventory, to ensure that parts are always in stock, while keeping a balanced level of inventory to maximize inventory turnover. Finally, Unknown Enterprise has strong vendor relationships with the most service conscious vendors who are capable of shipping major parts rapidly.

KEYS TO SUCCES.

Unknown’s Enterprise keys to success will include:

1. Practical and convenient auto repair services.
2. Honest and reliable services.
3. A wide range of auto parts inventory that is (nearly) never out of stock.
4. Great experienced in automotive world

COMPANY OWNERSHIP.

LIST OF SHAREHOLDERS.

SHAREHOLDER	CONTRIBUTIONS
MOHD AFNAN B. SUHAIMIN	34%
DANIEL B. ISMAIL	18%
MOHD LUTHFI B. SHAHABUDIN	16%
MUNAWWAR MUNIR B. ABD RAHIM	20%
WAN MOHD HAFIZULLAH B. WAN DERAMAN	12%

Unknown Enterprise is incorporated in the state of Pulau Pinang, Malaysia. It is owned by Mohd Afnan Suhaimin, Daniel Ismail, Mohd Luthfi Shahabudin, Munawwar Munir, and Wan Mohd Hafizullah where Mohd Afnan is the biggest shareholder of the company.

OUR LOCATION MAP.

No 2, Bangunan Lot Kedai Taman Sutera Prima,

13800, Seberang Jaya,Pulau Pinang,Malaysia.

Tel no.: 012-2346678/ 019-5654900

Fax no.: 608-565 8014

Company registration number: SA0102693-M

Date of starting the Business: 12-05-2012

Self Powered Vehicle Project

During my studies in diploma level, i has been assigned to designs a self powered vehicle that didn't required fuel or cells, the vehicle model must moved by using only mechanical mechanism. I and my group member had designed a model of BMW X6 and we use the mechanism of retraction, which in case cause the pulling and thus give the force to the tires to move,, 

FABRICATION PROCESS OF BMW X6 MODELS

PROVIDING MATERIAL AND TOOLS FOR BUILDING THE MODELS

To build our BMW X6 car, we first provide some materials and tools in order to build it. Majority of material s we used came from recycle material. We used some old box, bottles, soda can, old tyre tubes, old newspaper, and other things. For the tool to built our model, we used scissors, glue, staples, rulers, knife, and also screwdrivers.

 BUILDING THE CHASSIS OF THE MODELS.

In order to get better model for bmw x6, we had used our knowledge in chassis studies to built a better chassis for the models. Our frames was a ladder frame. This types of frames consist of side members and cross members. It was strong and can  support heavy loads. The materials we used was a wire casing as this types of materials was lighter, good in bending and also strong. This frames was built carefully and the dimensions was make sure to be accurate. Then, we riveted the cross members on to the side members. The cross members provides us mounting for the moving mechanisms and also the body of the model.

BUILDING THE BODY OF THE MODELS.

To built the body of the models, we uses old boxes as main materials for it. We used this types of materials because the flexibility of the box and also their contribution of weight for our bmw x6 models was less compared to other materials. Firstly, the box had been sketch all the dimension as needed by us. Then after the sketching had finished, we cut the box according to the sketch that we made. All the box  then had been joined together by cellophone tapes and also staples. All the bends and the critical place had been estimated precisely in order to get better results for our models.

 

APPLYING THE COLOUR TO THE MODELS.

After the body of the models had been finished, then come the moments for us to apply some colour to it. We used the spray paint due to ease of handling and cheap in price. All parts of the body had been sprayed with a maroon colour as it was the colour decided by both of us. After spraying the paint, it was allowed to dry in some minutes in order to make sure the paint does not wipe out.

 

 WHEEL CONSTRUCTING.

For our models to move smoothly in a tracks, the wheels had been constructed and attached to the frames. The materials for wheels that we used are soda can, papers, and also old tyre tubes that act as a surface of the wheels which will provide better grip for tractions. The tyres are held by steel rods that we get from the old steel hanger. The wheels was make sure to be balance in order for the car to move smoothly.

 

MECHANISMS FOR MOVINGS OF THE MODELS.

For moving, we used tape measure as the heart of the car. The reason for us to use this things  was absolutely because the tape measure could give a smooth and even movement of the car.

BMW X6 was a mid-size luxury vehicle produced by German automaker BMW. It was five door car and front engine all wheel drive vehicles. This type of model was so stylish and exclusive. On our project, we had been assign to built amodel of BMW X6 by recycled material and the mechanisms that can make the vehicle move also had been gave for us to think about. During the construction of our models, there are many challenging part that we had already face d in order to get a better model of this types of car. Management of cost, time and also materials was  been planned by us carefully to construct a better model. By looking at the cost that we had invest in order to complete this task, we firstly listed all the types of materials that we wanted to use for construction. As this task required us to used recycled materials or things, some of the cost had been reduced as the recycled material are easy to find and no charge for taking this materials. Although the budget had been reduced by the using of recycled parts, still there are some money to be spend on tools. So the proper list of things-to-get was made again in order to make sure all the budget flows in a correct way. The constructing of this models begin earlier before where we are assigned to built BMW X6 on SolidWorks Programming software. By using this softwares, an actual looks of BMW X6 was built in that programs and it was a better idea to make us more familiar to the models that we had to built. After the construction of the models in the programs, we then proceed our steps to built an actual looks or models of BMW X6. By using materials such as old box, bottles, soda can,wire casings, old tyre tubes and also newspaper, a model of BMW X6 was constructed. Many discussions that we had undergo in order to get better results and to avoid any errors that may come when least expectations was taken. The body of the models was built by old boxes. The use of this materials was very flexible and cost savings. Sketching of the car parts on the boxes was then been cut correctly. After all parts finished cutting, then we attached all the corresponding parts altogether with cellophane tapes and also staples. Using of staples makes the body of the model became more rigid eventhough not too strong. Then it comes for the frames of the models. The uses of wire case was very light and reduce the weight of the models if the models uses plywood or other things, this is because wire case was made up of plastics. On the upperside of the frames, there situated our moving mechanisms. We used tape measure as this things could move a car by springs pullback. The uses of this types of mechanisms also was very efficient as we can expects the length of travels of our cars. The strings was clamp at the axle of the wheel and before starts was make it or pull it under tensions. When the strings was released, the springs inside the tape measure will pull back the strings in its original situation, not in tension.

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