Chapter 4 Engine Removal Disassembly Inspection and InChassis

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

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 2

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

Vehicle Identification Number 4

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

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

Engine Removal 7

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 8

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

Engine Removal 10

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

Engine Removal 12

Engine Removal • Unbolt engine mounts • Remove engine 13

Engine Removal 14

Engine Disassembly • Remove any clutch parts 15

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 16

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

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

Engine Disassembly 19

Cylinder Block Disassembly • Remove ring ridge with ridge reamer 20

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

Cylinder Block Disassembly 22

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

Cylinder Block Disassembly 24

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

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 26