© 2012 delmar, cengage learning engine installation, break-in, and in-chassis repairs chapter 56

© 2012 Delmar, Cengage Learning

Engine Installation, Break-In, and In-Chassis Repairs

Chapter 56


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


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


Engine Installation and Install Engine Mounts

• Engine installation– 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


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


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


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


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

– Install valve covers

• 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


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


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


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


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


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


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


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


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


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


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


Removing the Oil Pan• Removing oil pan

– Could require removal of some steering linkage


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


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


Free-Wheeling and Interference Engines

• Freewheeling – 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


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


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

© 2012 delmar, cengage learning engine installation, break-in, and in-chassis repairs chapter 56

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