Study Guide Chapter 10 Pages 255 274 27 Points Be Certain to Read the Summary
Is there a career for me that melds 2 or more of my favorite clusters?
1. Major engine repair or overhaul will require from the vehicle, while some relatively major engine repairs on the upper end can be made with the engine still in the vehicle. Removal Replacement Rehearsal
2. No matter what the engine point will be, a first step preceding engine removal is cleaning the engine compartment with degreaser solution that emulsifies into a hot soapy solution with hot water. Entry Exit Lift
3. Protecting yourself with gloves and the vehicle with covers and disposable floor mats will result in more successful major engine work. Seat Roof Fender
4. Proceed by removing the, making electrical & fuel system, dealing with accessories like PS & AC, draining the engine, and disconnecting the exhaust system. Hood, Disconnects, Coolant
5. Drive line components like FWD shafts and RWD transmissions will have to be dealt with. Half Quarter Full
6. The torque converter must remain with the as the engine is removed. Depending on arrangement, transmission can stay in the car, be removed before engine, or be removed with engine. Engine Transmission Clutch
7. If bolting a to an engine, threads must go into the block a minimum of 1 ½ times their O.D. Sling Bling Chain
Engine Support Fixture
8. Once removed from the vehicle, the engine should be mounted on a as soon as possible. Stand Floor Bench
9. To assist with failure, cylinder heads as well as all wear mated parts should be marked, labeled & kept organized. Diagnosing Predicting Guessing
10. When loosening valve train components, valves may bend on engines that slam the valves into the pistons if they are out of time. That is not an issue with freewheeling engines. Interference Interruption Interrogative
11. Cylinder head bolts should be loosened or turns working from the of the head toward the center to prevent distortion. (Keep the head gaskets to compare with the new ones.) 1 or 2 3 or 4 5 or 6 Center Ends Middle
If either the camshaft or the lifters are damaged or worn, both should be Replaced since they are wear mated.
Removal of camshaft bearing caps on OHC engines must be done in steps sequentially to prevent distortion and breakage of the camshaft itself or the cam tower assembly.
A valve spring compressor is needed to remove the keepers from the valves. Keep all valve train parts in order for inspection and possible reuse. They too are wear mated.
Valve stems with peened or mushroomed tips must often be filed to get them out of the guide.
Valves that cannot be refaced without leaving 1/32 minimum margin must be replaced.
Timing components like sprockets, chains, belts & tensioners should be replaced during overhaul. They are often available as a service kit.
A ring ridge reamer is used to remove the cylinder ring ridge before pistons can be removed.
Use a center punch or number stamps to identify every connecting rod & cap and every main bearing cap before removal. Stamp them on the external flat surfaces.
Rod bolts should be covered with protectors to prevent crankshaft rod journal damage during removal.
Mark the flywheel/flex plate to maintain balance during reassembly.
It is wise to plastigage bearings at disassembly to determine wear, as well as during reassembly to determine new bearing clearance.
Remove all core plugs (freeze plugs) & oil gallery plugs prior to block cleaning.
For decisions on machining & parts ordering, measurements must be taken.
12. Cleaning methods depend upon the component to be cleaned and the of which it is made. Incorrect cleaning methods or agents could be more harmful than no cleaning at all! Year Material Country
13. Contaminants fall into 4 categories: 1) soils, 2) soils like petroleum by products combustion byproducts, & coatings, 3) rust, & 4) mineral deposits/scale. Water Soluble, Organic Soils
14. The 3 basic processes for cleaning automotive parts are: 1) cleaning, 2), and 3) cleaning. Chemical, Thermal, Abrasive
15. Parts washers, soak tanks, and hot spray tanks are examples of cleaning. Chemical Thermal Abrasive
16. cleaning ovens operate between 650 800 F to oxidize greases & oils into ash. Chemical Thermal Abrasive
17. Shot, tumbling, vibratory cleaning, and scraping with power tools are examples of the abrasive cleaning processes. Note: Shot Peening is different than Shot Blasting Blasting
18. Once parts are thoroughly cleaned, crack and repair can be done. Before repairing damaged engine parts, it is advisable to determine the cause of the fatigue & failure. Detection or Inspection
19. Common methods of crack detection are: 1) checks on a cylinder block or head, 2) (MPI) done to cast iron parts, also known as magnafluxing, and 3) penetrant, that can be done on iron as well as aluminum. Pressure Magnetic Particle Inspection Dye
Magnaflux method is applied for crack detection during crankshaft testing. The crank is previously soaked with a liquid which is sensitive to magnetism and ultraviolet light. The grinding process starts after each part has been measured very meticulously.