| Engine Replacement, Part 1 -- Preliminary Steps |
From "Weekend Mechanic"
episode WKM-205 |
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In this episode, Weekend Mechanic Bruce Bonebrake begins one of the biggest automotive procedures an amateur mechanic can undertake -- replacing an engine. This episode comprises the first half of this two-weekend project, and ends with the removal of the engine using an engine hoist. Whether it's through negligence (such as not changing the oil), a worn out gasket or just age, automotive engines sometimes fail. In some cases, the best approach is to simply replace the old, damaged engine with a new power-plant. The problem: The engine on this older vehicle (figure A) is completely nonfunctional. It has not run in quite some time, and is seized or "locked up." The timing belt is off, and there are strong indications of major internal engine damage. In fact, a hole is visible in the wall of the engine block. DIY Difficulty Rating for Repair: This job is sizable and quite involved. We gave it a difficulty rating of 5 on a 5-point intermediate-level scale. Part of the high ranking is that, in a job this big, there is a degree of uncertainty in terms of the complexity of the problems that we may encounter. We allotted two full weekends to complete this project. It took a total of about 24 hours to complete this job. Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools and when working beneath a vehicle. Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components. In addition to standard auto-mechanic's tools, some of the specialty tools that will be needed for this project include engine hoist, engine stand and a transmission jack. If you don't own these tools, you can rent them from most rental centers. An air-ratchet will also help speed up the repairs. Preliminary Steps and Diagnosis - The first step is to identify the exact type of engine that's in your vehicle so that you can order a suitable replacement. The vehicle identification number (VIN) will help you do this. The VIN is typically located on a plate on the dash, at the base of the windshield (figure B).
- The eighth character of the VIN (figure C) is the engine code for the vehicle. This indicates the type of engine that is designed for the vehicle. (It's a good idea to verify this by inspecting the engine as well to ensure that the engine you're replacing is not itself a modified or replacement engine.)
- Engine removal and replacement is a messy project. You may want to protect the floor of your garage and nearby equipment with plastic sheeting. Have plenty of shop rags and garage absorbent (figure D) handy to help with cleanup of spills, oil, fluids, etc.
- Make sure that you start this project on a solid, level surface, as an engine hoist will be used to lift the engine out of the vehicle, and the hoist will need to roll easily.
- On this engine, the fact that the cam-shaft can be manually turned by hand (figure E) indicates that the problem is most likely at the lower end of the engine.
- Inspection the dipstick indicates that there is no oil at all in the engine ( figure F) -- another ominous sign. Allowing a vehicle to run without oil can easily cause the engine to lock up.
- A hole is visible in the engine block, and the number-4 connecting rod is exposed.
- Before beginning disassembly on the engine, it's a good idea to label any parts that will be re-used when the new engine is installed. Masking tape and a large marker are ideal for this (figure G).
- It's also a good idea to take photos of your engine before disassembly begins, and at various phases throughout the project. The photos can be used for comparison and reference during re-assembly. Digital photos are especially useful for this.
- It's also important to disconnect the vehicle's negative battery cable (figure H) before disassembly begins.
- Start disassembly with the most accessible parts first, such as unbolting the air-filter assembly (figure I).
In the segment that follows, engine disassembly continues with accessories on the top-side of the engine.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
How Cars Work
Author: Tom Newton
ISBN: 0966862309
Publisher: Black Apple Press
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
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