Diagnose and repair light vehicle engines
Hsc
Chapter10_rev.pptxChapter 10
Engine
Disassembly and Cleaning
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Engine Removal Tips
Clean before beginning removal
Have the tools and equipment before you begin
Always follow removal procedures
Adhere to all safety guidelines
Use a digital camera or camcorder to record various locations and connections
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Engine Removal Preparation Video
Click on image above to play video
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General Removal Procedures
Install a battery memory saver
Remove hood and place in safe place
Drain fluids and remove oil filter
Disconnect linkages and electrical connections, label as necessary
Remove air intake components
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Labeling For Reassembly
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Disconnect and close off fuel lines
Label and disconnect vacuum lines
Remove drive belts and set power steering pump and air conditioning compressor aside
Disconnect heater and radiator hoses
Disconnect exhaust pipe
General Removal Procedures (Cont.)
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Engine Removal Video
Click on image above to play video
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FWD Engine Removal
Many FWD vehicles require the engine and transmission to be removed together as an assembly
Some FWD engines can be remove from above
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FWD Engine Removal (Cont.)
A transaxle support is necessary if the engine is removed from above
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FWD Engine Removal (Cont.)
Remove the axle shafts from the transaxle
Axles can usually be pried away from transaxle once the steering knuckle is separated from the lower control arm
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FWD Engine Removal (Cont.)
If possible, leave axles attached to hub assemblies
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RWD Engine Removal
The engine is usually removed from above through the hood opening
After all connections and components are removed, separate the engine from the transmission
Remove motor mount connections and remove the engine
Always support the transmission
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Engine Preparation
Once removed, mount securely to an engine stand
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Engine Preparation (Cont.)
Slowly disassemble and visually inspect the parts
Look for excessive wear on moving parts
Always follow the service procedures for proper disassembly and cleaning
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Cylinder Head Removal
Remove the intake and exhaust manifolds
Remove the valve cover or covers
Inspect for sludge
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Cylinder Head Removal (Cont.)
Disassemble rocker arm components
On OHC engines align timing marks and remove the timing belt
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Cylinder Head Removal (Cont.)
Keep all pushrods and rocker arm assemblies in exact order
Loosen cylinder head bolts one or two turns following the detorque sequence – often the reverse of the torque sequence
Inspect and save the head gasket
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Detorque Example
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Cylinder Head Removal Video
Click on image above to play video
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Knowledge Check
Why should cylinder heads bolts be loosened in reverse of the torque sequence?
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To help prevent warping the head.
20
Cleaning Engine Parts
After disassembly, parts should be thoroughly inspected and cleaned
The cleaning method depends on the component and the equipment available
Incorrect cleaning methods or agents can harm or destroy engine parts
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Water-Soluble Soils
Include dirt, dust, and mud
Organic Soils
Examples are oil, grease, and carbon
Rust
Results from a chemical reaction when iron and steel are exposed to oxygen and moisture
Scale
Results from minerals that have separated from water
Types of Soil Contaminants
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Chemical Cleaning
Uses a chemical reaction
Thermal Cleaning
Relies on heat to bake off soil
Abrasive Cleaners
Are usually used in conjunction with other cleaning processes
Three Basic Cleaning Processes
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Chemical Cleaning
Used to remove dirt, grease, scale, paint, and/or rust
Always wear the proper PPE when working with chemical cleaning agents
Hydrocarbon solvents require special handling and disposal
Some cleaners are water-based
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Chemical Cleaning Machines
Parts washers are commonly used and can soak, agitate, stream, and spray clean
Hot or cold soak tanks immerse components in cleaning solution to remove grease
Hot spray tanks use pressurized spray to decrease cleaning times
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Parts Cleaning Tank
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Thermal Cleaning
Uses heat to bake off or oxidize dirt and other contaminates
Becoming more popular because of reduced amount of hazardous wastes
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Abrasive Cleaners
Used in conjunction with other cleaning equipment
Shot and grit blasters used on parts that will later be machined
Parts tumblers used on small parts
Vibration cleaners or shakers use vibrating tub with abrasives to scrub parts
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Alternative Cleaning Methods
Ultrasonic cleaners uses high-frequency sound waves to clean parts
Citrus chemicals are safer to handle and easier to dispose of
Salt baths use high-temperature molten salt to dissolve carbon, grease, oil, dirt, paint, and some gasket materials
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Knowledge Check
Which type of engine cleaning has become the most popular and why?
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Thermal cleaning due the decreased amount of waste produced.
30
Crack Detection
Cleaned engine parts should be carefully inspected
Cracks result from pressure or temperature changes, fatigue from stress cycles, impact damage, and engine overheating
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Crack Detection Video
Click on image above to play video
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Cracked Lifter Bore
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Crack Detection Methods
Blocks and heads can be pressurized with air and placed into a water tank
Magnetic particle inspection magnetizes the metal
Dye penetrants are sprayed or brushed on the surface and when dry show cracks
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Magnetic Detection
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Dye Detection
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In-Vehicle Engine Service
Oil pan gasket replacement
Vibration damper replacement
Cylinder head replacement
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