Engine repair general description High mileage is not always a reliable indication of the need for an engine overhaul, while low mileage is not an obstacle to the need for a rebuild. Service frequency is...
Engine recovery options There are many engine overhaul options. The decision to replace the engine block, piston/rod assemblies and crankshaft depends on a number of factors, the most important...
Engine Removal — Methods and Precautions If it has been decided that the engine must be removed for repair, some preliminary steps must be taken. It is important to carefully prepare a suitable work area. It is...
Engine Repair — Dismantling Sequence 1. It is much easier to dismantle and operate the motor if it is mounted on a portable base. Before installing the engine on the frame, the flywheel/drive plate must be...
Cylinder head — removal Note: New and remanufactured cylinder heads are usually available from parts stores. Special tools are also not required, so you can replace the block head yourself. 1....
Cylinder head — cleaning and inspection 1. When thoroughly cleaning the cylinder head and associated valve components, perform a detailed inspection that will enable you to decide what work needs to be done...
Valves — service 1. Due to the complex nature of the job and the need for special tools and equipment, maintenance of valves, valve seats and valve guides is usually performed by a...
Cylinder head — bulkhead 1. Regardless of whether the block head has been repaired or not, thoroughly clean it before installation. 2. If the head was removed to repair valves and related...
Piston/Connecting Rod Assembly — Removal 1. First of all, it is necessary to grind off the protrusion formed by wear in the upper part of the cylinders. Use a special tool for this, following the manufacturer's...
Crankshaft — removal 1. Before the crankshaft is removed, check the end play. Set the micrometer with the stem in line with the crankshaft and just touch the end of the crankshaft (see...
Engine Block — Cleaning 1. Remove the soft plugs from the engine block. To do this, punch them into the block using a hammer and punch, then take them with large pliers and pull them out...
Engine Block — Inspection 1. Thoroughly clean the engine block as described in Chapter 13 , and double check to make sure the ridge on top of each cylinder has been completely removed. 2....
Camshaft — inspection 1. After the camshaft has been removed from the engine, clean it with solvent and dry, inspect the bearing journals for uneven wear, corrosion, or the possibility of...
Piston/Connecting Rod Assembly — Inspection 1. Before inspection, the piston/rod assembly must be cleaned and the piston rings removed from the pistons. Note: Always use new piston rings when reassembling the...
Crankshaft — inspection 1. Clean crankshaft with solvent and dry thoroughly. Lubrication holes must also be cleaned (stiff brush) and washed with solvent. Remove all traces of solvent with...
Main and connecting rod bearings — inspection 1. Do not throw away the old main and connecting rod bearings after they have been replaced, inspecting them can provide valuable information regarding the condition of...
Piston rings — installation 1. Before installing new piston rings, check the piston ring gaps. This takes into account that the side clearance of the piston ring on the piston has been checked and...
Back cover and oil seal — installation 1. Lightly lubricate the outer edge of the oil seal with engine assembly oil or clean engine oil, and place the oil seal into the hole in the rear cover. Fully seat the...
Engine Overhaul — Assembly Sequence 1. Before assembling the engine, prepare all necessary replacement parts, gaskets and seals, as well as the following: Standard set of tools torque wrench Piston ring...
Starting and running after a bulkhead 1. Install the engine in the engine compartment and check the engine oil and coolant levels. 2. Remove the spark plugs from the engine, ground the ignition coil high...