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
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