NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING

SPRING 2023
ME-431 IC ENGINE AND POWERPLANT LAB

Disassembly and Assembly of intake and exhaust manifolds and cylinder head
of Toyota 2F engine.
S.NO NAME TEAMWORK INDIVIDUAL TOTAL
ASSESMENT
1 Abd ul Hannan
2 Ahmed Hasan Khan
3 Burhan ur Rehman
1. Title:
Disassembly and Assembly of intake and exhaust manifolds and cylinder head of Toyota
2F engine.

2. Objectives:
1. Understand the function and operation of the intake and exhaust manifolds in the
Toyota 2F engine.
2. Disassemble and inspect the intake and exhaust manifolds for wear or damage.
3. Clean and reassemble the intake and exhaust manifolds, ensuring proper sealing and
alignment.
4. Evaluate the performance of the intake and exhaust manifolds after reassembly.
3. Apparatus:
Toyota 2F engine, Screwdriver set, T-spanner, Combination spanner set, Socket Set,
Torque Wrench

4. Disassembly and Assembly of intake and exhaust manifolds and cylinder

head of Toyota 2F engine.
Disassembly Procedure:
• Disconnect the negative battery cable.
• Drain the coolant from the radiator and remove the upper radiator hose.
• Remove the air cleaner assembly and throttle body.
• Disconnect the fuel lines and remove the fuel injectors.
• Remove the intake manifold bolts and remove the manifold.
• Remove the exhaust manifold bolts and remove the manifold.
• Remove the rocker cover bolts and remove the cover.
• Remove the camshaft holder bolts and remove the holder.
• Remove the camshaft sprocket bolts and remove the sprocket.
• Remove the timing belt cover bolts and remove the cover.
• Loosen the timing belt tensioner bolt and remove the belt.
• Remove the cylinder head bolts in the proper sequence and remove the head.
Assembly Procedure:
• Clean the cylinder head, intake manifold, and exhaust manifold mating surfaces thoroughly.
• Install the new cylinder head gasket onto the engine block.
• Install the cylinder head onto the block and tighten the bolts in the proper sequence to the
specified torque.
• Install the timing belt and adjust the tensioner.
• Install the camshaft sprocket and torque the bolts to the specified value.
• Install the camshaft holder and torque the bolts to the specified value.
• Install the rocker cover and torque the bolts to the specified value.
 • Install the exhaust manifold and torque the bolts to the specified value.
• Install the intake manifold and torque the bolts to the specified value.
• Install the fuel injectors and connect the fuel lines.
• Install the air cleaner assembly and throttle body.
• Install the upper radiator hose and fill the cooling system with coolant.
• Reconnect the negative battery cable.
• Start the engine and check for leaks or abnormal noises.
Tools:
The specific tools required for the disassembly and assembly of the distributor, self-starter, and
generator on a Toyota 2F four-stroke Overhead Valve spark ignition engine is following:
• Socket set and wrenches of various sizes for removing bolts and nuts.
• Pliers for removing and installing various clips and connectors.
• Screwdrivers of various sizes for removing and installing screws.
• Timing light for setting the ignition timing.
• Multimeter for testing electrical components.
• Puller tools for removing the distributor rotor and pulleys.
• Torque wrench for tightening bolts to the correct specification.
• Bearing puller and installer for removing and installing bearings.
• Seal puller and installer for removing and installing seals.
• Feeler gauge for checking valve clearance.
It's important to note that some of these tools may not be necessary for every task during the
disassembly and assembly process. It's recommended to consult the engine's service manual for
specific instructions and tool requirements.

5. Observations:
• The intake and exhaust manifold and cylinder head are key components of the engine,
responsible for controlling the flow of air and exhaust gases into and out of the combustion
chamber.
• The cylinder head may contain components such as the valves, valve springs, and rocker
arms.
• Remove the cylinder head bolts in the proper sequence and remove the head.
Measurements
• 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ 𝑒𝑒𝑒𝑒𝑒𝑒 𝑡𝑡𝑡𝑡 𝑒𝑒𝑒𝑒𝑒𝑒 = 127.74 𝑚𝑚𝑚𝑚
• 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 7.97 𝑚𝑚𝑚𝑚
• 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑒𝑒𝑒𝑒𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 37.40 𝑚𝑚𝑚𝑚
• 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 exhaust valve = 95.85 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔
• 125.1 𝑚𝑚𝑚𝑚 = 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑒𝑒𝑒𝑒𝑒𝑒 𝑡𝑡𝑡𝑡 𝑒𝑒𝑒𝑒𝑒𝑒
• 7.92 𝑚𝑚𝑚𝑚 = 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑑𝑑𝑑𝑑𝑑𝑑
• 46.22 𝑚𝑚𝑚𝑚 = 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑒𝑒𝑒𝑒𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑
 • Mass intake valve = 116.75 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔
• 8.99 𝑚𝑚𝑚𝑚 = 𝑃𝑃𝑃𝑃𝑃𝑃ℎ𝑟𝑟𝑟𝑟𝑟𝑟 𝑑𝑑𝑑𝑑𝑑𝑑
• 276 𝑚𝑚𝑚𝑚 = 𝑝𝑝𝑝𝑝𝑝𝑝ℎ𝑟𝑟𝑟𝑟𝑟𝑟 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ 𝑒𝑒𝑒𝑒𝑒𝑒 𝑡𝑡𝑡𝑡 𝑒𝑒𝑒𝑒𝑒𝑒
Photos

pushrod

Rocker arm

FIGURE 1 TOP VIEW OF CYLINDER BLOCK WITH CYLINDER HEAD REMOVED(LEFT) AND CYLINDER BLOCK
DISASSEMBLY (RIGHT)

camshaft

FIGURE 2 TOYOTA 2F ENGINE CUT SECTION SIDE VIEW (LEFT) AND FRONT VIEW (RIGHT)
Maintenance issues:
• Common maintenance issues with the intake and exhaust manifold and cylinder head may
include worn or damaged valve components, exhaust leaks, or carbon build-up on the
valves or cylinder head.
• These issues can lead to reduced engine performance, decreased fuel efficiency, or even
engine failure.
Improvements:
 • Replacing worn or damaged valve components can improve engine performance and
prevent further damage to the engine.
• Repairing exhaust leaks can improve fuel efficiency and reduce harmful emissions.
• Cleaning carbon build-up from the valves and cylinder head can improve engine breathing
and performance.

6. Discussion:
During the disassembly and assembly of the intake and exhaust manifold and cylinder head of a
Toyota 2F engine, students may learn about the key components of the engine responsible for
controlling air and exhaust flow, and how to diagnose and repair common issues. Alternatives to
complete disassembly and assembly may include replacing individual components such as valves
or rocker arms or repairing specific issues such as exhaust leaks or carbon build-up. Failure modes
for the intake and exhaust manifold and cylinder head may include issues such as worn or damaged
valve components, exhaust leaks, or carbon build-up, which can lead to poor engine performance
or even engine failure. Regular maintenance procedures should be performed to prevent these
issues, such as inspecting and replacing worn or damaged components, repairing exhaust leaks, or
cleaning carbon build-up.

7. Safety Precautions:
1. Personal Protective Equipment (PPE): Wear appropriate safety gear, such as gloves, safety
glasses, and closed-toe shoes, to protect yourself from sharp edges, hot surfaces, and debris.
2. Engine Temperature: Ensure the engine is cool before starting the disassembly or assembly
process to prevent burns or injury from hot surfaces and fluids.
3. Disconnect the Battery: Disconnect the vehicle's battery before working on the engine to
prevent electrical shock, short circuits, or unintentional activation of components.
4. Ventilation: Work in a well-ventilated area to avoid inhaling harmful fumes from chemicals,
engine fluids, or exhaust gases.
5. Use Proper Tools: Use the correct tools for each task, and ensure they are in good condition
to prevent accidents or damage to the engine components.
6. Secure the Vehicle: Make sure the vehicle is securely supported on level ground, with the
parking brake engaged and wheel chocks in place, if necessary, to prevent movement
during the procedure.
7. Follow Manufacturer's Guidelines: Consult the vehicle's service manual for specific
instructions, torque specifications, and sequences to avoid causing damage to the engine or
components.
8. Clean Work Area: Keep the work area clean and free from debris, tools, and fluids to
prevent slips, trips, and falls.
9. Handle Chemicals Safely: Use appropriate containers and handling techniques when
working with chemicals, such as brake cleaner or penetrating oil. Follow the manufacturer's
instructions for use and disposal, and wear appropriate PPE, such as gloves and safety
glasses, to prevent skin and eye irritation.
10. Lifting and Carrying: Use proper lifting and carrying techniques when handling heavy or
bulky components, such as the intake and exhaust manifolds, to prevent injury. Ask for
assistance or use mechanical aids, if necessary.
11. Stay Organized: Label and organize parts, fasteners, and connections during disassembly
to ensure accurate reassembly and prevent damage or incorrect installation. This can also
help prevent lost or misplaced components.
12. Stay Informed: Continually update your knowledge on best practices and safety guidelines
related to automotive repair and maintenance. This will help you stay safe and efficient in
your work.