Disassemble Engine Parts and repair steps.pdf

Disassembling engine parts and repair steps

1. 1
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING
CHAPTER 49 – MODERN AUTOMOTIVE
TECHNOLOGY

2. 2
Engines are removed when the cylinder
block or crankshaft is badly damaged

When in doubt, always refer to a
manufacturer’s service manual.

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

3. 3
To prepare for engine removal, use the
following general steps and a shop manual.

1.Park the vehicle so there is plenty of work space on
both sides and in front of the engine compartment
2.Use fender covers to protect the paint.
3.Scribe the hood along the hinges to aid realignment,
then have someone help you remove the hood. Store
the hood in a safe place where it cannot be damaged
4.Disconnect the battery to prevent an electrical short
and fire. Remove the battery if it is in the way.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

4. 4
5. Drain the engine oil and coolant
6.Unplug all electrical wires between the engine and
chassis. If needed, use masking tape to label or identify
the wires.
7.Remove all coolant and vacuum hoses that prevent
engine removal. Label vacuum hoses if necessary for
proper reconnection
8.Disconnect the throttle cable a the throttle body
9.When disconnecting fuel lines, be careful not to let fuel
spray out. Wrap a shop rag around the hose or fitting
during disconnection

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

5. 5
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

6. 6
10.Keep fasteners organized in several different
labeled containers.
10.Do not disconnect any power steering or air
conditioning lines unless absolutely necessary. Usually
they can be unbolted from the block and placed to the
side of the engine compartment
11.Remove the radiator, fan, and other accessory units in
front of the engine. Be careful not to hit or drop the
radiator. Only remove parts that hinder engine removal.
12.Remove any other part that prevents engine removal;
exhaust header pipe, automatic transmission flywheel
fasteners, and bell housing bolts.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

7. 7
Before Engine removal, double check:

1.Behind and under the engine for hidden wires or ground
straps
2.That the bell housing bolts are out
3.To see that you have removed the torque converter
bolts
4.That all fuel lines are disconnected and plugged
5.That a floor jack or other piece of equipment is
supporting the transmission
6.That motor mounts are unbolted
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

8. 8
Transmission Removal

It is sometimes necessary to remove the engine and
transmission together. Some front-wheel-drive vehicles that
use a transaxle require that the two be removed as a unit.
Check the service manual for details.
You may want to drain the transmission if it is going to be
removed.
With rear-wheel-drive vehicles the drive shaft, transmission
and clutch linkages, speedometer cable, rear motor mount
and other parts must also be removed. With a transaxle,
the axle shafts must be disconnected / removed
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

9. 9
Installing a Lifting Fixture

Connect the lifting fixture or chain to the engine at the
recommended lifting points
If a chain is being used be sure to use large enough bolts
and washers to hold the weight and prevent the load from
slipping loose
Generally, position the fixture or chain so that it will raise
the engine in a level manner.
Use common sense and follow manufacture’s instructions
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

10. 10
Lifting the Engine

Attach the lifting device
Slowly raise the engine about an inch or two, then check
that everything is out of the way and disconnected
Continue raising the engine while pulling forward to
separate the engine from the transmission – Do not let the
engine bind or damage parts
Once clearance is sufficient roll the crane and engine away
from the vehicle
Some engine/transmission assemblies are removed from
under the vehicle rather than the top
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

11. 11
Lifting the Engine

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

12. 12
Warning

Never work on an engine
that is held by a crane or
hoist. The engine could
shift and fall, damaging
the engine or causing
serious injury!
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

13. 13
Warning

Never place any part
of your body under
an engine held in the
air. A heavy engine
can chop off finger,
cripple, or even kill
you if dropped!
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

14. 14
Lifting the Engine

Attach the lifting device
Slowly raise the engine about an inch or two, then check
that everything is out of the way and disconnected
Continue raising the engine while pulling forward to
separate the engine from the transmission – Do not let the
engine bind or damage parts
Once clearance is sufficient roll the crane and engine away
from the vehicle
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

15. 15
Lifting the Engine

Some engine/transmission assemblies are removed from
under the vehicle rather than the top
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

16. 16
Engine Disassembly

With the engine bolted to the engine stand or sitting on
blocks you are ready to begin teardown.
During engine teardown, go slowly, and inspect each part
for signs of trouble. Look for wear, cracks, damage, seal
leakage, and gasket leakage.
If you overlook one problem your repair may fail in service
making all your service for nothing.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

17. 17
Engine Top End Disassembly Guide

Remove external engine parts (carburetor, fuel rail or
throttle body unit, spark plug wires and distributor).
Take off all parts that could be damaged or prevent the
removal of the cylinder head.

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

18. 18
Engine Top End Disassembly Guide

If you are not familiar with the engine take special note
about how everything fits together (take pictures!) –
Always align the timing marks on the chain, gears or
belt before removal.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

19. 19
Engine Top End Disassembly Guide

Remove the valve covers, exhaust manifolds and intake
manifold - If light prying is needed be careful not to
damage the mating surfaces.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

20. 20
Engine Top End
Disassembly Guide

Keep groups of fasteners organized
in different containers.

Inspect gasket surfaces for leakage,
warpage and scratches – if
warped surfaces should be
machined


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

21. 21
Engine Top End Disassembly Guide

With V-type push rod engine, you may need to remove the
valve train components before the intake manifold. The
push rods can pass through the bottom of the intake.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

22. 22
Engine Top End Disassembly Guide

If the lifter, pushrods, and rocker arms are to be reused,
keep them in exact order. Use an organizing tray (tray or
board with holes in it for push rods and lifters) or label
these parts with masking tape – Wear patterns and
select-fit parts require that most components be
installed in their original location.



ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

23. 23
Engine Top End Disassembly Guide Cont.

Use a Valve spring compressor to compress the valve
springs. This will allow you to lift off the keepers
As you remove the valve, valve springs, keepers & retainers,
keep them organized – it is best to return them to the
same location in the cylinder head.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

24. 24
Engine Top End Disassembly Guide Cont.

Check for mushroomed valve stems (stem tip enlarged and
smashed outward by rocker arm action) – A file must be
used to cut off the mushroomed tip before valve
removal, if forced out it could score the inside of the
valve guide and head.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

25. 25
Engine Front end Disassembly Guide

Remove the water pump and any other parts bolted in
front of the engine timing cover – If a timing belt is used
remove its cover, loosen the tensioner and slip off the
belt (this will have to be done before cylinder head
removal)


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

26. 26
Engine Front end Disassembly Guide

Do not attempt to rotate the crankshaft of an overhead cam
engine with the timing belt off (cylinder head still in
place) – The pistons could slide up and hit the valves.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

27. 27
Engine Front End Disassembly Guide

A wheel puller is normally needed to remove the harmonic
balancer or damper – the balancer is usually press fit
onto the crankshaft.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

28. 28
Engine Front End Disassembly Guide

Unbolt and remove the timing chain or gear cover. – If
prying is necessary, do is lightly while tapping with a
rubber hammer. Do not bend or scar mating surfaces.
Remove the oil slinger and timing mechanism – Usually the
timing gears or sprockets will slide off after light taps
with a brass hammer (if not use a puller).


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

29. 29
Engine Bottom End Disassembly Guide

After top and front end disassembly, you are ready to take
the bottom end apart. The bottom end typically
includes the pistons, rods, crankshaft, and related .
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

30. 30
Engine Bottom End Disassembly Guide

Inspect the cylinders for signs of excess wear – Use your
fingernail to feel for a lip or ridge at the top of the
cylinder wall.
A cylinder ridge or ring ridge may be formed at the top of
the cylinder walls, where ring friction does not wear the
cylinders – A ridge reaming tool is needed to cut out and
remove a ridge at the top of a worn cylinder. Removing
this ridge will prevent piston damage upon removal.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

31. 31
Engine Bottom End Disassembly Guide

Ridge reamer

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

32. 32
Engine Bottom End Disassembly Guide

Use compressed air to blow metal shavings out of the
cylinder after ridge reaming – This will prevent cylinder
or piston scoring.
Unbolt and remove the oil pan and oil pump. Inspect the
bottom of the oil pan for debris – Metal chips and
plastic bits may help you diagnose and find engine
problems.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

33. 33
Engine Bottom End Disassembly Guide

Unbolt on of the connecting rod caps, then use a wooden
hammer handle to tap the piston and rod out of the
cylinder.


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

34. 34
Engine Bottom End Disassembly Guide

As soon as the piston is out replace the rod cap and check
the piston head and connecting rod for identification
markings – The piston will usually have an arrow
pointing to the front of the engine. The connecting rod
and cap should have numbers matching them to the
proper cylinder
If needed mark the pistons with arrows and the
connecting rod and cap with appropriate markings –
Severe engine damage if these are installed wrong


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING
FRONT OF ENGINE

35. 35
Engine Bottom End Disassembly Guide

Remove all of the oil rings from their pistons – Spiral the
rings off with your fingers or use a ring expander

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

36. 36
Engine Bottom End Disassembly Guide

If the vehicle has a manual transmission check for flywheel
warpage – Use a dial indicator setup, if out of
specification send to a machine shop for resurfacing.

ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

37. 37
Engine Bottom End Disassembly Guide

Before removing the main bearing caps make sure they are
numbered – Normally numbers and arrows are cast on
each cap (the number 1 cap is at the front of the
engine).


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

38. 38
Engine Bottom End Disassembly Guide

If the main bearing caps are mixed up, the crank bore may
be misaligned and the crank can lock in the bore and
main bearings during reassembly

Unbolt the main caps – To remove them wiggle back and
forth while pulling, then lift the crankshaft carefully out
of the block (do not hit or nick the journals).


ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

39. 39
Engine Bottom End Disassembly Guide

If the engine is old, pry out the block and head core or
freeze plugs – They rust out and will leak after
prolonged serviced, this must also be done if the engine
block is going to be boiled (cleaned in strong chemicals
at machine shop to remove mineral deposits in water
jackets).
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

40. 40
Engine Bottom End Disassembly Guide

If the cylinders have deep ridges, the block must be sent to
a machine shop for boring and hot tank cleaning – Make
sure all external hardware (motor mount brackets, oil
and coolant temperature sending units) are removed.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

41. 41
Cleaning Engine Parts

After removal of all parts everything should be cleaned
– Different cleaning techniques are needed depending
upon part construction and type of material.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

42. 42
Cleaning Engine Parts

Closer part inspections can be done after cleaning
– Problems can be hard to see when a part is covered
with oil, grease, or carbon deposits.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

43. 43
Cleaning Engine Parts

Begin engine parts cleaning by scraping off all old gasket
material and hard deposits – Use a dull scrapers and
work carefully when cleaning soft aluminum parts (the
slightest nick could cause leakage when returned to
service.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

44. 44
Cleaning Engine Parts

When using a gasket scraper, push the scraper away from
your body, not toward your body. A scraper can inflict
serious cuts
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

45. 45
Cleaning Engine Parts

Gasket remover is a chemical that dissolves old gasket
material and sealer to aid in part cleaning – If needed,
spray the remover over the material after scraping. Wait
a few minutes and then scrape the dissolved residue off
the part.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

46. 46
Cleaning Engine Parts

There are several power cleaning tools – If used properly,
they can speed up and ease engine repairs.
A power brush is driven by an air or electric drill to remove
hard carbon. It is especially handy inside hard-to-reach
areas such as combustion chambers.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

47. 47
Cleaning Engine Parts

A wire wheel on a bench grinder is another common
method of cleaning engine parts. – Frequently it is used
to clean carbon off valves (keep the safety shield and
tool rest in place)
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

48. 48
Cleaning Engine Parts

Scuff pads are hard plastic cleaning wheels that mount in a
drill for cleaning parts – They are better to use on
aluminum and plastic engine parts because they will not
erode metal as easy as a steel cleaning brush will.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

49. 49
Cleaning Solvent

After cleaning off the gaskets, use cleaning solvent to
remove hard to reach deposits – Cold soak tanks
(solvent tanks) are cleaning machines for removing oil
and grease from parts. (will not remove hard carbon or
mineral deposits)
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

50. 50
WARNING

Never use gasoline to clean parts. The slightest spark or
flame could ignite the fumes, causing a deadly fire!
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

51. 51
Cleaning Solvent

Hot tanks are large cleaning machine filled with strong,
corrosive chemical. – Will remove mineral deposits in
the water jackets, hard carbon deposits, oil , grease, and
even paint. Automotive machine shops normally have a
hot tank.

CAUTION
Aluminum components can be corroded or etched by
soaking in a hot tank
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

52. 52
Special Cleaning tools

A ring groove cleaner is used to scrape carbon from inside
piston ring grooves. – Common tool used during piston
service, the groove cleaner is rotated around the piston.
A scraper bit the same size as the groove removes the
carbon.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

53. 53
Special Cleaning tools

A valve guide cleaner is inserted into each valve guide. An
electric or air drill spins the tool to remove deposits.
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

54. 54
Special Cleaning tools

An air blow gun is normally the last method of cleaning
parts. It uses pressure from the shop’s air compressor to
blow off small bits of dirt, solvent, water and other
debris.
When using an air blow gun, direct the blast of air into all
pockets and holes in parts. This will prepare the parts
for reassembly.
Warning
Use extreme care when using an air gun. Wear goggles and
avoid aiming the gun at your body. If air bubbles enter
your bloodstream, the result could be DEATH
ENGINE REMOVAL, DISASSEMBLY, & PARTS CLEANING

55. 55
ENGINE MECHANICAL PROBLEMS - REVIEW
What are some proper, appropriate methods of disassembling an
engine?






Note the lengths and organize bolts in containers

Inspect gasket mating surfaces

Keep critical parts organized so they can be installed in
the same location

56. 56
ENGINE MECHANICAL PROBLEMS - REVIEW
Are air conditioning line to be removed from an engine? Why or
why not?






No, not unless they have been evacuated, there are toxic
chemicals (freon) in the lines.

57. 57
ENGINE MECHANICAL PROBLEMS - REVIEW
When servicing a vehicle with a manual transmission, the
______________ should be checked for warpage (runout)






Flywheel

58. 58
ENGINE MECHANICAL PROBLEMS - REVIEW
Are power steering hoses usually disconnected during engine
removal?






No, the are removed from the engine and placed aside
out of the way. (not opening the system)

59. 59
ENGINE MECHANICAL PROBLEMS - REVIEW
Is it required to always remove the engine to remove the oil pan
from it?






No, some oil pans can be removed from the engine
without removing the engine from the vehicle.

60. 60
ENGINE MECHANICAL PROBLEMS - REVIEW
What do you have to do to the battery before removing anything
from the engine compartment?






Disconnect it, remove it if needed.

61. 61
ENGINE MECHANICAL PROBLEMS - REVIEW
Is it always necessary to remove the engine from the vehicle to
replace piston rings?






No, some piston rings can be changed with the engine
still in the vehicle.

62. 62
ENGINE MECHANICAL PROBLEMS - REVIEW
When removing a manual transmission with an engine what must
you disconnect from the transmission?






Shifter linkages

63. 63
ENGINE MECHANICAL PROBLEMS - REVIEW
All fuel lines must be disconnected and plugged when removing an
engine from a vehicle.






True False

64. 64
ENGINE MECHANICAL PROBLEMS - REVIEW
Ground straps must not be disconnect when removing an engine
from a vehicle






True False






Ground straps must be disconnected from the engine before
removal

65. 65
ENGINE MECHANICAL PROBLEMS - REVIEW
How do you remove a valve with a “mushroomed tip” on it from
the head of an engine?






File off the “mushroomed tip” and then carefully take out
the valve.

66. 66
ENGINE MECHANICAL PROBLEMS - REVIEW
How do you remove a harmonic balancer from a crankshaft?






Using a wheel puller

67. 67
ENGINE MECHANICAL PROBLEMS - REVIEW
Is a “ring ridge” removed before or after piston removal?






Before, so the piston can come out easily

68. 68
ENGINE MECHANICAL PROBLEMS - REVIEW
What is the tool called used to remove a “ring ridge”?






Ridge reamer

69. 69
ENGINE MECHANICAL PROBLEMS - REVIEW
A hot tank is the best way to clean an aluminum head from an
engine.






True False






Hot tanks will corrode or etch aluminum

70. 70
ENGINE MECHANICAL PROBLEMS - REVIEW
The number one main bearing cap is located at the transmission
end (back) of the engine.






True False






It is located at the front (timing end) of the engine

71. 71
ENGINE MECHANICAL PROBLEMS - REVIEW
What will a cold soak tank NOT remove from parts?






Hard carbon
Mineral deposits

72. 72
ENGINE MECHANICAL PROBLEMS - REVIEW
Repairs to the cylinder head and valve train normally require
engine removal.






True False






Most cylinder heads can be removed for service without engine
removal.

73. 73
ENGINE MECHANICAL PROBLEMS - REVIEW
A wire wheel is commonly used to clean carbon from valves.






True False

74. 74
ENGINE MECHANICAL PROBLEMS - REVIEW
The radiator and fan are normally removed during engine removal.






True False

75. 75
ENGINE MECHANICAL PROBLEMS - REVIEW
All engines are removed from above.






True False






Some engines need to be removed from under the vehicle

76. 76
ENGINE MECHANICAL PROBLEMS - REVIEW
List at least 3 check to do right after lifting an engine a couple
inches out of its chassis.






Hiding wires or ground straps
Bell housing bolts are removed
Torque converter bolts removed (automatic trans.)
Fuel lines are disconnected and plugged
Transmission is supported
Motor mounts are unbolted

77. 77
ENGINE MECHANICAL PROBLEMS - REVIEW
Why should you support the transmission after engine removal?






Damage to the rear rubber mount or drive shaft could
occur

78. 78
ENGINE MECHANICAL PROBLEMS - REVIEW
When using a chain to lift an engine from a vehicle and using a
bolt, nut and washer to support the chain, what do you need to be
careful of?






The bolt, nut and washer combination used is large
enough to not slip through the chain when tension from
the engine’s weight is applied to it.

79. 79
ENGINE MECHANICAL PROBLEMS - REVIEW
Are you ready for a Test???






If YES…..GREAT!
If NO…..Start studying!

Remember to write out notes by hand.