Group 9 - GM Inline Four Cylinder Engine

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Executive Summary

Group 9 received a 2.2 liter 4 cylinder GM engine for their Reverse Engineering Project. The engine was nonoperational when received but otherwise in good condition. This project was completed in cooperation with group 24. The engine was divided amongst the two groups with group 9 being responsible for the belt drive system, camshaft and crankshaft. Group 24 on the other hand was responsible for the header and pistons. The project was to be completed over the course of a semester and was broken down into 5 stages or gates.

Gate 1 is the Request for Proposal. In this a work proposal is laid out. The work proposal discusses the overview of the work plan, the tools and time required, and the group's capabilities and shortcomings. Gate 1 also lays out a management proposal. The management proposal gives an overview of the management plans. This lays out the responsibilities of each member and the role they will play. This also assigns each person a leadership role based on their expertise. Meeting times are also planned out as well as a plan to resolve conflicts. Gate 1 also deals with the initial product assessment. This is where several questions about the product are answered based on an initial assessment.

Gate 2 is the Preliminary Design Review. This is where the product is dissected and documented with images illustrating how the engine was taken apart. A difficulty is assigned to each task as well as details whenever difficulties occur. A cause for corrective action is also here detailing further how problems were resolved and how well the previously discussed plans (management and work) played out.

Gate 3 is the Coordination Review. Here each part is analyzed in detail post disassembly. Each part is analyzed in terms of function, shape, material, manufacturing process, and the forces acting on it. Upon analyzing the parts design revisions are proposed to improve the product. To increase the thoroughness of the review certain parts were solid modeled while others were analyzed with engineering analysis.

Gate 4 is the Critical Project Review. This is where the product was reassembled while keeping the same level of detail as when the product was dissected. At this point the product was reevaluated compared to before the disassembly.

Gate 5 is the delivery. This includes finishing the wiki accompanied by a compliance matrix ensuring the completion of all parts. This stage also encompasses an oral presentation of the results of the project.

The project was successful in achieving the outlined objectives (refer to introduction). The product was disassembled and reassembled successfully while being analyzed along the way. Below are the results of this project.


The main objective of this project was to dissect and analyze an assigned product. Group 9 was given a 2.2 liter 4 cylinder gm engine. The engine was nonfunctioning upon the start of the project. Understanding how products work and how to apply engineering logic to real world products is a very important skill to develop for engineers. This project reinforced these key skills as well as allowed for the improvement of group working skills. This project also gave a chance to showcase technical writing skills and decision making skills.


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