1. Engine Installation, Break-In, and In-Chassis Repairs
Chapter 56

2. 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

3. 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

4. Engine Installation and Install Engine Mounts
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

5. 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 all previously disconnected parts
Install fuel system components
Install oil filter and add oil

7. 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

9. 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

10. Install Valve Covers Oil is apparent at some of the rocker arms
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

11. 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

12. 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

13. 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

14. 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 45mph to 50mph
Coast back to 45 mph several times
May take 2,000 to 3,000 miles to seat the rings

15. 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

16. 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

17. 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

18. 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

20. 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

21. 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

22. Removing the Oil Pan Removing oil pan
Could require removal of some steering linkage

23. 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

25. 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

26. Free-Wheeling and Interference Engines
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

27. 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

28. 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