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

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

Vehicle Identification Number

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

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

Engine Removal

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

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

Engine Removal

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

Engine Removal

Engine Removal Unbolt engine mounts Remove engine

Engine Removal

Engine Disassembly Remove any clutch parts

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

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

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

Engine Disassembly

Cylinder Block Disassembly Remove ring ridge with ridge reamer

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

Cylinder Block Disassembly

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

Cylinder Block Disassembly

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

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