1. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Chapter 10 Engine Disassembly and Cleaning

2. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Engine Removal Tips Clean before beginning removal Have the tools and equipment before you begin Always follow removal procedures Adhere to all safety guidelines Use a digital camera or camcorder to record various locations and connections

3. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. General Removal Procedures Install a battery memory saver Remove hood and place in safe place Drain fluids and remove oil filter Disconnect linkages and electrical connections, label as necessary Remove air intake components

4. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Labeling For Reassembly

5. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Disconnect and close off fuel lines Label and disconnect vacuum lines Remove drive belts and set power steering pump and air conditioning compressor aside Disconnect heater and radiator hoses Disconnect exhaust pipe General Removal Procedures (Cont.)

6. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. FWD Engine Removal Many FWD vehicles require the engine and transmission to be removed together as an assembly Some FWD engines can be remove from above

7. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. FWD Engine Removal (Cont.) A transaxle support is necessary if the engine is removed from above

8. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. FWD Engine Removal (Cont.) Remove the axle shafts from the transaxle Axles can usually be pried away from transaxle once the steering knuckle is separated from the lower control arm

9. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. FWD Engine Removal (Cont.) If possible, leave axles attached to hub assemblies

10. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. RWD Engine Removal The engine is usually removed from above through the hood opening After all connections and components are removed, separate the engine from the transmission Remove motor mount connections and remove the engine Always support the transmission

11. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Engine Preparation Once removed, mount securely to an engine stand

12. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Engine Preparation (Cont.) Slowly disassemble and visually inspect the parts Look for excessive wear on moving parts Always follow the service procedures for proper disassembly and cleaning

13. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Cylinder Head Removal Remove the intake and exhaust manifolds Remove the valve cover or covers Inspect for sludge

14. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Cylinder Head Removal (Cont.) Disassemble rocker arm components On OHC engines align timing marks and remove the timing belt

15. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Cylinder Head Removal (Cont.) Keep all pushrods and rocker arm assemblies in exact order Loosen cylinder head bolts one or two turns following the detorque sequence – often the reverse of the torque sequence Inspect and save the head gasket

16. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Detorque Example

17. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Knowledge Check Why should cylinder heads bolts be loosened in reverse of the torque sequence?

18. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Cleaning Engine Parts After disassembly, parts should be thoroughly inspected and cleaned The cleaning method depends on the component and the equipment available Incorrect cleaning methods or agents can harm or destroy engine parts

19. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Water-Soluble Soils – Include dirt, dust, and mud Organic Soils – Examples are oil, grease, and carbon Rust – Results from a chemical reaction when iron and steel are exposed to oxygen and moisture Scale – Results from minerals that have separated from water Types of Soil Contaminants

20. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Chemical Cleaning – Uses a chemical reaction Thermal Cleaning – Relies on heat to bake off soil Abrasive Cleaners – Are usually used in conjunction with other cleaning processes Three Basic Cleaning Processes

21. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Chemical Cleaning Used to remove dirt, grease, scale, paint, and/or rust Always wear the proper PPE when working with chemical cleaning agents Hydrocarbon solvents require special handling and disposal Some cleaners are water-based

22. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Chemical Cleaning Machines Parts washers are commonly used and can soak, agitate, stream, and spray clean Hot or cold soak tanks immerse components in cleaning solution to remove grease Hot spray tanks use pressurized spray to decrease cleaning times

23. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Parts Cleaning Tank

24. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Thermal Cleaning Uses heat to bake off or oxidize dirt and other contaminates Becoming more popular because of reduced amount of hazardous wastes

25. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Abrasive Cleaners Used in conjunction with other cleaning equipment Shot and grit blasters used on parts that will later be machined Parts tumblers used on small parts Vibration cleaners or shakers use vibrating tub with abrasives to scrub parts

26. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Alternative Cleaning Methods Ultrasonic cleaners uses high-frequency sound waves to clean parts Citrus chemicals are safer to handle and easier to dispose of Salt baths use high-temperature molten salt to dissolve carbon, grease, oil, dirt, paint, and some gasket materials

27. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Knowledge Check Which type of engine cleaning has become the most popular and why?

28. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Crack Detection Cleaned engine parts should be carefully inspected Cracks result from pressure or temperature changes, fatigue from stress cycles, impact damage, and engine overheating

29. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Cracked Lifter Bore

30. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Crack Detection Methods Blocks and heads can be pressurized with air and placed into a water tank Magnetic particle inspection magnetizes the metal Dye penetrants are sprayed or brushed on the surface and when dry show cracks

31. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Magnetic Detection

32. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. Dye Detection

33. © 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied, duplicated, or posted to a publicly accessible website, in whole or in part. In-Vehicle Engine Service Oil pan gasket replacement Vibration damper replacement Cylinder head replacement