Engine Installation BreakIn and InChassis Repairs Chapter 56
Engine Installation, Break-In, and In-Chassis Repairs Chapter 56 © 2012 Delmar, Cengage Learning
Objectives • Install an engine in a vehicle • Pre-lube and make all required adjustments prior to starting an engine • Inspect and complete the job following engine starting and break-in • Overhaul an engine while it is in the vehicle © 2012 Delmar, Cengage Learning
Introduction • This chapter describes: – How to install an engine in a vehicle • After installation, certain procedures are followed to break it in – Some repairs done to an engine while it is in the vehicle © 2012 Delmar, Cengage Learning
Engine Installation and Install Engine Mounts • Engine installation – Be sure fender covers are installed – Be careful when using a chain hoist • Chain may nick the car’s paint • Install engine mount – Install bolts loosely on the block – Mounts are more easily aligned with frame mount brackets © 2012 Delmar, Cengage Learning
Install the Engine • Major steps – Raise and position engine in the engine compartment – Use a rolling head prybar when aligning bolts – Bolt the engine to the transmission housing – Install previously disconnected parts – Install fuel system components – Install oil filter and add oil © 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Priming the Lubrication System • Prime the system by driving the oil pump – Drive tool with a slow drill – Engines with hydraulic filters or cam followers • Turn pump until pressure builds • Turn crankshaft one complete revolution – Turn the pump once more • Distributor must have gear on bottom of its shaft – Otherwise oil pump priming will be impossible © 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Pressure Priming • Not possible to prime by removing distributor – Use a pressure primer – Remove all spark plugs and crank engine • Pressure primer uses – Prime the system – Check excessive bearing clearance – Check for sufficient oil pressure – Flush oil galleries during in-car engine repair • Remove oil pan and block off oil pump inlet – Some pumps must be filled with assembly lube © 2012 Delmar, Cengage Learning
Install Valve Covers • Oil is apparent at some of the rocker arms – Install valve covers • Oil is not reaching the valve area during priming – Double-check to see that an internal oil leak does not exist • Before installing the valve covers – Easier to position the engine at top dead center (TDC) on number one © 2012 Delmar, Cengage Learning
Ignition System Installation and Timing • Predominant designs – Distributor and distributorless • Major steps – Align timing mark on damper with pointer on timing cover – Before starting engine: fill coolant overflow reservoir at least half full © 2012 Delmar, Cengage Learning
Engine Starting and Initial Break -In • First few minutes of operation are critical – Temperatures must be controlled • When engine is first run, check: – Oil pressure – Coolant temperature – Oil leaks • Shut engine off immediately if adjustments are needed © 2012 Delmar, Cengage Learning
Valve Clearance Adjustment • Mechanical valve clearance adjustment – Clearance set during engine assembly – Done with engine off • Attempting an overhead cam (OHC) adjustment with the engine running can be messy © 2012 Delmar, Cengage Learning
Road Test and Break-in • Take safety precautions before the test drive – Double-check hose connections and fluid levels – With key off, push accelerator to WOT • Seat the piston rings – Drive on freeway – In high gear: • Accelerate from 45 mph to 50 mph • Coast back to 45 mph several times – May take 2, 000 to 3, 000 miles to seat the rings © 2012 Delmar, Cengage Learning
Final Inspection • Major steps – Double-check the engine for oil leaks – Make certain all wires and lines have been correctly installed – Check all warning lights or gauges are operating properly – If malfunction indicator comes on, determine cause of DTC and repair © 2012 Delmar, Cengage Learning
Returning the Car to the Customer • Major considerations – Return in a clean condition – Raise the hood and explain what was done – Return to shop after 500 miles for checkup • Customer break-in procedures – No excessive engine idle for first three hours • • Keep in normal rpm range: first two to three hours Engine speed: should vary Full load or high-speed operation: should be limited After high-load operation: allow engine to return to a stable operating temperature © 2012 Delmar, Cengage Learning
Engine Repair-Engine in the Vehicle • Technicians often perform major repairs to an engine while it is in the vehicle – Rebuilding cylinder heads – Lower end work – Overhaul: piston ring and crank bearing replacement • OHC engines – Many require a new chain tensioner © 2012 Delmar, Cengage Learning
Valve Job or Head Gasket Repairs • Major steps – Unbolt head in direction opposite to normal tightening sequence – Check cleanliness of head bolt threads – Be careful that nothing is accidentally pinched between head and block when reinstalling – Maintain valve timing • Keep the timing chain or belt in place © 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Valve Job or Complete Engine Overhaul and Head Gasket Problems • Valve guide seals – Responsible for some oil consumption complaints • Inspect head gasket for damage – Excessive temperatures can turn a metal head gasket blue or black – Teflon® gaskets can turn brown – Look for signs of coolant leaks © 2012 Delmar, Cengage Learning
In-Chassis Lower End Repairs • Low-mileage engine – Often repaired without removing the engine – Engine hoist can be used to raise engine and remove oil pan © 2012 Delmar, Cengage Learning
Removing the Oil Pan • Removing oil pan – Could require removal of some steering linkage © 2012 Delmar, Cengage Learning
Remove the Piston and Rod Assembly • Major steps – Lower end is to be repaired: remove cylinder heads – In-car repair might call for replacement of one defective piston – Main bearings are replaced with the crankshaft in the engine – Bearings must be rolled out on side opposite bearing locating lug © 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Remove the Timing Cover • Major steps – Remove radiator – Remove accessory drive belts – Remove vibration damper • Service on belt drives – Relatively simple • Removing timing cover on some OHC engines with timing chains is more difficult © 2012 Delmar, Cengage Learning
Free-Wheeling and Interference Engines • Freewheeling – An engine that has enough piston-to-valve clearance to prevent contact • Before a chain repair job – Perform a leakage test on non-freewheeling engines • Check for bent valves © 2012 Delmar, Cengage Learning
Replace the Timing Components and Crankshaft Seal Replacement • Reinstalling the head on an OHC engine – Number one piston is at TDC and cam is properly timed • Drive sprockets – Replaced with engine in the car • Crankshaft front and rear seal replacements – Performed with engine in the car © 2012 Delmar, Cengage Learning
Flywheel Ring Gear Service • Most vehicles with standard transmissions have a replaceable ring gear on flywheel – Flywheel ring gear can be worn by a defective starter motor drive • Heat the new ring gear evenly around its circumference during installation – Tempilstick® checks ring gear temperature – Polishing and solder can also be used to check temperature of ring gear © 2012 Delmar, Cengage Learning
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