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© © 2012 Delmar, Cengage Learning Engine Removal and Disassembly Chapter 50.

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Presentation on theme: "© © 2012 Delmar, Cengage Learning Engine Removal and Disassembly Chapter 50."— Presentation transcript:

1 © © 2012 Delmar, Cengage Learning Engine Removal and Disassembly Chapter 50

2 © © 2012 Delmar, Cengage Learning 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

3 © © 2012 Delmar, Cengage Learning 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

4 © © 2012 Delmar, Cengage Learning 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

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7 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

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9 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

10 © © 2012 Delmar, Cengage Learning 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

11 © © 2012 Delmar, Cengage Learning 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

12 © © 2012 Delmar, Cengage Learning 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

13 © © 2012 Delmar, Cengage Learning 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

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16 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

17 © © 2012 Delmar, Cengage Learning Overhead Cam Cylinder Head Removal 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

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19 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

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21 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

22 © © 2012 Delmar, Cengage Learning 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

23 © © 2012 Delmar, Cengage Learning 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

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25 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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