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Engine Removal and Disassembly. Chapter 50. Objectives. Label and organize parts prior to engine removal Remove an engine from a vehicle in a safe and methodical manner Disassemble the engine following the correct procedures Keep parts organized for reassembly

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Presentation Transcript
objectives
Objectives
  • Label and organize parts prior to engine removal
  • Remove an engine from a vehicle in a safe and methodical manner
  • Disassemble the engine following the correct procedures
  • Keep parts organized for reassembly
  • Inspect and interpret causes internal engine wear
introduction
Introduction
  • Procedures must be followed carefully
    • Parts must be removed and inspected in an orderly manner
      • You cannot hurry
      • Signs of wear can be clues
      • Correct repair will prevent the problem from occurring again
    • Be sure to consult the applicable repair manual
      • Procedures differ
engine removal
Engine Removal
  • Important steps
    • Disconnect battery cables
    • Remove the hood
    • Remove air cleaner
    • Label all wires and vacuum lines
    • Drain coolant and oil
    • Remove the radiator
    • Remove the distributor and spark plug wiring
    • Remove the direct current (DC) generator
    • Remove the heater hoses and ground strap
engine removal cont d
Engine Removal (cont'd.)
  • Remove switches and sensors
  • Remove the throttle linkage, cable, or wiring
  • Mark accessory brackets and remove accessories
  • Remove exhaust components
  • Remove and plug the fuel line
  • Determine whether to remove the transmission
  • Separate the engine and transmission/transaxle
  • Unbolt the engine mounts
engine removal cont d9
Engine Removal (cont'd.)
  • Remove the engine from the vehicle
  • Remove transaxle (if necessary)
    • Remove lower ball joints
      • Have drain pan ready
    • Disconnect speedometer cable, transmission shift linkage, and clutch cable
    • Attach a sling to the engine and transaxle assembly
    • Remove bolts
    • Roll shop crane until the engine can be lowered safely
engine disassembly
Engine Disassembly
  • Important steps
    • Remove clutch parts
    • Remove hybrid armature (puller required)
    • Mount engine to a stand
    • Remove coolant pump
    • Remove oil pan
    • Remove valve covers
      • Slip a knife blade between head and sheet metal valve cover
      • Tap a curved, strong area with a rubber mallet
engines with pushrods
Engines with Pushrods
  • Stud mounted rockers
    • Loosen nuts on studs before disassembly and cleaning
    • Turn rocker arms to the side to remove the pushrods
    • After heads are cleaned they can be removed one at a time
    • Keep pushrods in order
engines with pushrods cont d
Engines with Pushrods (cont'd.)
  • Shaft-mounted rockers
    • Should be loosened slowly and evenly
    • Remove the pushrods
    • Pushrods can be pushed through holes made in a piece of cardboard
    • Pushrods must be kept in order
engines with pushrods cont d13
Engines with Pushrods (cont'd.)
  • Valve lifters
    • Remove valve lifters
    • Wipe oil off bottom of lifters
    • Label with a felt marker
    • Reused flat tappers must be used on original cam lobe
      • Usually replaced
    • Roller lifters are usually reusable
    • Use chemical cleaner to soften varnish
engines with pushrods cont d16
Engines with Pushrods (cont'd.)
  • Pushrod engine camshaft
    • Some pushrod engines use bolt-on cam thrust plate
    • Varnish may builds up on edges of cam journals
      • Makes it difficult to remove the cam
  • Vibration damper removal
    • Most engines have a bolt that holds it on the crankshaft
      • Some will slip off after the bolt is removed
    • Others are pressed-fit
overhead cam cylinder head removal
Overhead Cam Cylinder HeadRemoval
  • Important steps
    • Position the number one piston at TDC and note the location of timing marks
    • Compare the sketch in the repair manual to the marks on the timing belt
    • Draw a sketch of the cam timing
    • Remove timing cover
overhead cam engines cont d
Overhead Cam Engines (cont'd.)
  • Remove the cam drive assembly
    • Pushrod engines
      • Unbolt cam sprocket and slide or pry off the cam
      • Remove the chain
      • Reinstall sprocket and tighten one bolt finger tight
    • Overhead cam engines
      • Remove the chain or bolt tensioner
overhead cam engines cont d21
Overhead Cam Engines (cont'd.)
  • Remove the cylinder heads
    • Mark one of the cylinder heads “left” or “right” if there is more than one
    • Be careful not to break a casting
  • Inspect the head gasket
    • Evidence of coolant or oil leakage
    • Signs of detonation
cylinder block disassembly
Cylinder Block Disassembly
  • Modern engines use premium piston rings
    • Will not accommodate a worn cylinder bore
  • Ridge causes
    • Pressure of combustion forcing the piston ring against the cylinder wall
    • Lack of clean lubrication at the top of the cylinder
cylinder block disassembly cont d
Cylinder Block Disassembly (cont'd.)
  • Important steps
    • Turn engine over and mark main caps and rod caps
    • Main caps must be installed in one direction only
    • Connecting rods and caps are mated to one another and must be marked for identification
    • Remove and inspect the piston and rod assembly
    • Inspect the piston, rings, rod, and bearings
    • Remove the crankshaft and inspect for wear
    • Remove the camshaft
cylinder block disassembly cont d25
Cylinder Block Disassembly (cont'd.)
  • Remove and label cam bearings
  • Remove core plugs
  • Clean engine parts
  • Remove the crank sprocket or gear
  • Finish diagnosis and repair of engine assembly
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