1. Engine Removal, Disassembly, Inspection, and In-Chassis Repairs
Chapter 4
Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

2. Objectives Locate repair information in shop manuals
Safely and properly remove an engine from a vehicle
Disassemble an engine in an orderly matter
Select the most appropriate method of engine repair

3. Vehicle Identification Number
Located on plate attached to dashboard
Consists of 17 digits
Eighth digit represents engine code
Tenth digit represents model year

4. Vehicle Identification Number

5. Repair Information Generic service manuals Electronic service manuals
Technical service bulletins
Hotline services
Internet
Magazines
Parts and Labor Estimating

6. Engine Removal Disconnect battery
Remove air cleaner and label all wires and connectors
Drain coolant and oil

7. Engine Removal

8. Engine Removal Remove in this order: Hood Radiator
Distributor and spark plug wires
Alternator and accessory wiring
Heater hoses and ground strap
Switches and sensors

9. Engine Removal Bleed fuel system pressure Remove and plug fuel line
Remove intake manifold
Mark accessory brackets and remove accessories

10. Engine Removal

11. Engine Removal Remove exhaust components
Determine if transmission will be removed with engine
Separate transmission from engine

12. Engine Removal

13. Engine Removal
Unbolt engine mounts
Remove engine

14. Engine Removal

15. Engine Disassembly
Remove any clutch parts

16. Engine Removal Hybrid Armature Removal
Location of the motor/generator usually behind engine
Permanent magnet rotor is bolted to back of crankshaft
A puller is required to remove

17. Engine Disassembly Mount engine on stand Remove coolant pump
Remove oil pan
Remove valve covers

18. Engine Disassembly Remove vibration damper Remove timing cover
Remove cam drive assembly
Remove cylinder head(s)

19. Engine Disassembly

20. Cylinder Block Disassembly
Remove ring ridge with ridge reamer

21. Cylinder Block Disassembly
Mark main and rod caps
Remove and inspect pistons and connecting rods

22. Cylinder Block Disassembly

23. Cylinder Block Disassembly
Inspect pistons, rings, rods, and bearings
Remove crankshaft and bearings
Reinstall main caps onto block
Remove camshaft

24. Cylinder Block Disassembly

25. Cylinder Block Disassembly
Remove and label cam bearings
Remove core plugs
Clean the engine

26. Major Engine Repair – In Vehicle
Valve job or head gasket repair
Remove oil pan
Remove piston and rod assembly
Rod bearing replacement
Remove timing cover
Timing chain and belt service