1. DISASSEMBLE ENGINE Teknik Kendaraan Ringan Semester 3 th Class XI Kompetensi Kejuruan SK-KD 6 TH

2. DIAGRAM ALUR PENCAPAIAN KOMPETENSI

3. TEKNOLOGI DAN REKAYASA 3 REASSEMBLE ENGINE PROCEDURE

4. Partial engine An engine with the auxiliary components and intake and exhaust manifold removed. The largest of the engine supply states. Partial engine Exhaust manifold Intake manifold Auxiliary component (Alternator) TEKNOLOGI DAN REKAYASA 4 PARTS OF COMPONENT

5. 1. Remove Water Pump Pulley 2. Remove Engine Mounting Bracket 3. Remove Crankshaft Pulley 4. Remove Water Pump 5. Remove Timing Chain Cover 6. Remove Timing Chain 7. Inspect Timing Chain 8. Remove Camshaft 9. Inspect Camshaft Timing Gear 10. Remove Camshaft Timing Gear/ Sprocket 11. Remove Cylinder Head 12. Remove Cylinder Head Gasket 13. Remove Oil Pan 14. Remove Oil Seal TEKNOLOGI DAN REKAYASA 5 REMOVE ENGINE PARTS

6. 1. Remove Water Pump Pulley (1) Water pump pulley Water pump pulley TEKNOLOGI DAN REKAYASA 6 REMOVE ENGINE PARTS

7. 2. Remove Engine Mounting Bracket (1) Engine mounting bracket Engine mounting bracket TEKNOLOGI DAN REKAYASA 7 REMOVE ENGINE PARTS

8. 3. Remove Crankshaft Pulley Crankshaft pulley TEKNOLOGI DAN REKAYASA 8 REMOVE ENGINE PARTS

9. 1. Set position of piston (1) Set the timing mark of crank pulley to "0", and No. 1 cylinder to the compression TDC (Top Dead Center), so that the camshaft timing mark faces upward. HINT : Make a note of this point to facilitate subsequent disassembly and reassembly. No.1 cylinder compression TDC (Top Dead center) Camshaft timing mark Crankshaft timing mark TEKNOLOGI DAN REKAYASA 9 SET PISTON POSITION

10. SST (Crankshaft pulley holding tool, Companion flange holding tool) SST (Puller C set) 2. Remove crank shaft pulley (1) Using SST, hold the crankshaft pulley and remove the bolts. (2) Using SST, remove the crankshaft pulley. TEKNOLOGI DAN REKAYASA 10 REMOVE ENGINE PARTS

11. 4. Remove Water Pump (1) Water pump (2) Gasket Water pump Gasket TEKNOLOGI DAN REKAYASA 11 REMOVE ENGINE PARTS

12. Cylinder head cover Gasket Timing chain cover 5. Remove Timing Chain Cover TEKNOLOGI DAN REKAYASA 12 REMOVE ENGINE PARTS

13. Timing chain cover Tape 1. Remove cylinder head cover and gasket 2. Remove timing chain cover (1) Remove all bolts and nuts. (2) Insert a flat-head screwdriver between the chain cover and the cylinder head and block. After that pry off the chain cover. TEKNOLOGI DAN REKAYASA 13 REMOVE ENGINE PARTS

14. 6. Remove Timing Chain Chain tensioner Chain tensioner slipper Timing chain Chain tensioner slipper TEKNOLOGI DAN REKAYASA 14 REMOVE ENGINE PARTS

15. 1. Remove chain tensioner (auto tensioner) Release the chain tensioner tension. The plunger of the chain tensioner is designed so that the ratchet mechanism only allows the plunger to fly out and does not allow it to be pushed inward. Move the stopper plate, release the ratchet mechanism, push in the plunger, and then loosen the timing chain. CAUTION: Removal of the chain tensioner while the timing chain is still under tension could cause the chain tensioner to fly out, resulting in injury, so be sure to relax the timing chain tension. 2. Remove chain tensioner slipper 3. Remove chain vibration damper Chain tensioner Plunger Stopper plate Timing chain Chain tensioner slipper TEKNOLOGI DAN REKAYASA 15 REMOVE ENGINE PARTS

16. 4. Remove timing chain Remove the timing chain without using excessive force. 5. Set piston position Move the piston downward by rotating the crankshaft 40 degrees counterclockwise from the TDC (Top Dead Center). HINT: Because rotating the crankshaft with the chain tensioner or chain removed could cause the valve and piston to interfere with each other, lower the piston. Camshaft sprocket timing mark Timing chain mark plate Crankshaft timing sprocket timing mark Timing chain mark plate TEKNOLOGI DAN REKAYASA 16 REMOVE ENGINE PARTS

17. Inspect the degree of elongation of the timing chain. Hang the chain from any hook on the wall. Next, pull the chain by applying a constant pressure with a spring balance. Using vernier calipers, measure the reference number of guides of length. As the pin and bushing wear, free play increases. This results in stretching of the timing chain as a whole. Therefore, measure the length of the timing chain to judge if it can be reused. HINT: Replace the chain if the measured value exceeds the specified value. Correct valve timing cannot be obtained if the timing chain elongates too much. Refer to the Repair Manual for the specified value. Vernier calipers Spring balance Pin Bush Timing chain TEKNOLOGI DAN REKAYASA 17 TIMING CHAIN

18. 8. Remove Camshaft Bearing cap Camshaft Bearing cap TEKNOLOGI DAN REKAYASA 18 REMOVE ENGINE PARTS

19. 1. Set camshaft position bolts (1) Set the camshaft position so that the valve spring force is uniformly applied to the camshaft and where it can be removed horizontally. HINT: The camshaft setting position differs according to the particular type of engine. Refer to the Repair Manual for further details. 2. Remove camshaft (1) Uniformly loosen and remove the bearing cap mounting bolts several times. (2) Remove the bearing cap and camshaft. HINT: The order of removal for the bearing cap mounting bolts differs according to the engine type. Refer to the Repair Manual for further details. (3) Store the removed bearing cap in the cylinder No. order. TEKNOLOGI DAN REKAYASA 19 CAM SHAFT

20. 1NZ-FE engine: For the camshaft timing gear (with VVT-i), when the engine stops, the lock pin locks the vane and the housing by the spring force. When the engine starts, oil pressure is applied to the lock pin to release it. For this reason, the lock/unlock action of the lock pin needs to be inspected. Lock Unlock Lock pin Oil pressure Housing Vane Housing Lock pin Housing Vane Inspect Camshaft Timing Gear (with VVT-i) TEKNOLOGI DAN REKAYASA 20

21. For a lock pin, applying the engine pressure to the retard side unlocks the lock. For inspection, compressed air is used instead of the engine oil pressure. 1. Apply compressed air to both the advance side and retard side. HINT: Applying compressed air to both the advance side and retard side prevents the timing gear from moving suddenly when the lock pin is released. 2. Lessen the compressed air on the retard side and move the timing gear to the advance side. HINT: The difference of the compressed air pressure between advance side and retard side moves the timing gear to the advance side. Retard side Advance side Retard side Advance side TEKNOLOGI DAN REKAYASA 21 Inspect Camshaft Timing Gear (with VVT-i)

22. 3. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path. NOTICE: If the order for taking off compressed air is not followed, the timing gear moves to retard side suddenly, which could damage the timing gear. 4. With the lock pin unlocked, make sure that the timing gear can be turned smoothly by hand when it is in any position except for the most retard side. 5. Turn the timing gear to the most retard side, and make sure that it locks. Retard side Advance side TEKNOLOGI DAN REKAYASA 22 Inspect Camshaft Timing Gear (with VVT-i)

23. Camshaft timing gear (with VVT-i) Camshaft timing sprocket (without VVT-i) 10. Remove Camshaft Timing Gear/Sprocket TEKNOLOGI DAN REKAYASA 23 REMOVE ENGINE PARTS

24. Unlock Lock pin Camshaft Aluminium plate Vise Camshaft timing gear (with VVT-i) Flange bolt 1. Remove camshaft timing gear (with VVT-i) (1) Apply compressed air to unlock the lock pin. (2) Turn the timing gear to the most advance side. (3) Remove the flange bolt to remove the timing gear. NOTICE: If the flange bolts are removed while the lock pin remains locked, horizontal force is exerted on the lock pin, which might damage it. Remove only the flange bolts. The timing gear cannot be disassembled. TEKNOLOGI DAN REKAYASA 24 REMOVE ENGINE PARTS

25. Cylinder head 11. Remove Cylinder Head TEKNOLOGI DAN REKAYASA 25 REMOVE ENGINE PARTS

26. 1. Remove cylinder head bolts (1) Loosen and remove the cylinder head mounting bolts in order from outside to inside. 2. Remove the cylinder head Tap the rib portion with a plastic hammer to remove the cylinder head. HINT : When the head is removed, water and oil will leak from the water jacket and the oil hole. When placing the removed head on a working bench or a disassembly pan, lay a cloth on the bench or pan and let it absorb the oil to keep the working area clean. TEKNOLOGI DAN REKAYASA 26 REMOVE ENGINE PARTS

27. Cylinder head gasket 12. Remove Cylinder Head Gasket (1) Cylinder head gasket TEKNOLOGI DAN REKAYASA 27 REMOVE ENGINE PARTS

28. Drain plug Gasket Oil pan No.1 Oil pan No.2 Oil strainer Gasket 13. Remove Oil Pan TEKNOLOGI DAN REKAYASA 28 REMOVE ENGINE PARTS

29. SST (Oil pan seal cutter) Oil pan No.2 Oil pan No.1 1. Remove oil pan No.2 The oil pan is sealed with seal packing. Therefore, detach the seal packing using SST. NOTICE: Do not turn the engine over before removing the oil pan No.2, or sludge and metal particles left in the oil pan may enter the pistons and cylinders, which could damage the inside wall of the cylinders. Therefore, do not turn the engine over until oil pan No.2 is removed. 2. Remove oil pan No.1 Turn the engine over. Using a flat- head screwdriver, remove oil pan No.1 by prying between the cylinder block and oil pan No.1. TEKNOLOGI DAN REKAYASA 29 REMOVE ENGINE PARTS

30. Timing chain cover oil seal Engine rear oil seal 14. Remove Oil Seal TEKNOLOGI DAN REKAYASA 30 REMOVE ENGINE PARTS

31. Timing chain cover oil seal Engine rear oil seal Cloth 1. Remove timing chain cover oil seal Pry off the oil seal using a screwdriver. NOTICE: Place a cloth over the timing chain cover in order to protect it from damage. 2. Remove engine rear oil seal Remove the engine rear oil seal from the crankshaft. TEKNOLOGI DAN REKAYASA 31 REMOVE ENGINE PARTS

32. 1. Inspect Chain Tensioner 2. Inspect Camshaft Timing Sprocket 3. Inspect Chain Tensioner Slipper and Damper 4. Inspect Cylinder Head Set Bolt TEKNOLOGI DAN REKAYASA 32 REMOVE ENGINE PARTS

33. Plunger Stopper plate Chain tensioner Ratchet pawl Plunger Stopper plate Ratchet pawl If there is trouble with the chain tensioner, it will no longer be possible to apply tension to the timing chain, which will cause the timing chain to become loose and cause skipping, which could damage the valve mechanism. 1. When raising the ratchet pawl, check that the plunger can be moved by finger. 2. When moving the ratchet pawl back, check that the plunger locks. HINT: Make sure that the plunger moves smoothly without resistance. Replace the tensioner if it malfunctions. TEKNOLOGI DAN REKAYASA 33 CHAIN TENSIONER

34. Vernier calipers Sprocket Timing chain Sprocket wear causes the chain to rest too deeply on the sprocket, reducing the outside diameter of the chain when it is mounted over the sprocket. Therefore, mount the chain over the sprocket and then measure the outside diameter of the chain to judge whether the sprocket is normal. Allowing the sprocket wear to progress may cause tooth missing or tooth skipping due to the loose chain, which may result in damage to the valve mechanism. TEKNOLOGI DAN REKAYASA 34 CHAIN TENSIONER

35. Chain tensioner slipper Chain vibration damper The areas where the slipper and damper are in contact with the timing chain become worn. When this happens, the timing chain begins to vibrate, at which time the tensioner can no longer apply the proper tension to the timing chain, causing the timing chain to become loose and cause skipping, which could damage the valve mechanism. TEKNOLOGI DAN REKAYASA 35 CHAIN TENSIONER

36. Vernier calipers Cylinder head bolt The cylinder head is mounted with plastic region bolts. Since these bolts gradually elongate every time they are used, measure the length and outside diameter of each bolt to judge if it can be reused. TEKNOLOGI DAN REKAYASA 36 Cylinder head bolt

37. Timing belt tensioner Cloth The timing belt tensioner uses a spring to apply tension to the timing belt. Tension release method (1) Loosen the bolts and. (2) Push the pulley in the direction where the belt is not mounted and temporarily tighten the bolt. (3) Tighten the bolt loosely to hold the tensioner in place. NOTICE: Wrap a cloth or other material around the belt tensioner to keep it from being damaged. TEKNOLOGI DAN REKAYASA 37 Tension release method

38. TEKNOLOGI DAN REKAYASA 38 BIBLIOGRAPHY: TEAM 21 “Toyota Technician”, Toyota Astra Motor