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Mastering Engine Repair Techniques: Removal, Disassembly, and Inspection Handbook

Learn to safely remove, disassemble, and inspect engines, locate repair information, identify vehicles, and conduct in-chassis repairs efficiently. This comprehensive guide covers essential procedures and techniques for successful engine repair and maintenance.

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Mastering Engine Repair Techniques: Removal, Disassembly, and Inspection Handbook

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  1. Chapter 4 Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

  2. 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

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

  4. Vehicle Identification Number

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

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

  7. Engine Removal

  8. 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

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

  10. Engine Removal

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

  12. Engine Removal

  13. Engine Removal • Unbolt engine mounts • Remove engine

  14. Engine Removal

  15. Engine Disassembly • Remove any clutch parts

  16. 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

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

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

  19. Engine Disassembly

  20. Cylinder Block Disassembly • Remove ring ridge with ridge reamer

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

  22. Cylinder Block Disassembly

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

  24. Cylinder Block Disassembly

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

  26. 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

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