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.