dev kumar mahato assembly 2
TRANSCRIPT
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Engine assembly
NAME=DEV KUMAR MAHATO
U.ROLL. NO.= 7626147
COLLEGE ROLL NO.=1240775
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Engine assembly
Before final cleaning
• Remove all sharp edges created by machining
• Clean all internal & external threads
Combustion chamberCrankshaft oil holes Top & bottom of cylindersOil pump gears
Chamfer top of bolt holesUse tap or die for restoring threads
Copyright 2003 Gary Lewis – Dave Capitolo
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Engine assembly
Before final cleaning
• Check lifter bores for rust & burrs
• Check cam bores for burrs
Use glaze breaker if necessary
Could distort cam bearings if not deburred
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Engine assembly
Final cleaning
• Only after all machining is done
• Use detergent hot tank
• Insufficient cleaning results in . . . Piston ring wearBearing wearValve stem wear
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Engine assembly
Final cleaning
• Coat cylinders & decks with clean oil to prevent rust
• Coat valves, seats, & decks with clean oil
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Engine assembly
Assembling cylinder heads
• Guides must be clean & lubricated
• Install valves with oil• Protect seals with plastic sleeve on valve
• Check cam rotation on OHC heads
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Engine assembly
Installing core plugs
• Measure bore diameter to assure correct plugs
• Use deep plugs where possible• Coat outer edges for sealing
• Drive plug in slightly below block surface
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Engine assembly
Sealing coolant, lubricants, & combustion
• Typical cooling system is 15 PSI @ 230°F
• Typical oil pressure range is 20-80 PSI
• Gasket must not restrict flow• Fire rings protect gasket material & cyl pressure
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Engine assembly
Chemical sealers
• Sometimes used in place of gaskets
• Silicone sealers (RTV) are flexible & temp resistant
• Anaerobic sealers – Absence of air
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Engine assembly
Head gaskets
• Metal-asbestos replaced with ceramic laminate
• Composite core copperGood compressibility, low compression, 60AA
• Composite core steelHeat resistant, high compression, 60AA
• Coated gasketsResin, polymer, better sealing of fluids
• MLS (Multi layer steel)For dissimilar metals, 15-20AA
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Engine assembly
Head gaskets
• Stainless steel faceOn one side for high cylinder head temps,GM diesels
• Embossed steelImproved heat transfer, ridges provide crush for sealing, high compression, 30-50AA
• No-retorquePolymer coated, printed with silicone for low clamping force areas
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Engine assembly
Gaskets
• Cork used on valve covers, lifter covers, oil pansStretches & shrinks
• Synthetic rubberCompressible, does not wick, resists heat
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Engine assembly
Crankshaft seals
• Rope type seals must be fitted
• Lip type sealsLips face the oil
• Nitril & neoprene are common• Viton withstands loads & heat
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Engine assembly
OHV assembly
• Only after sub-assemblies have been inspected
• Install core plugs • Install chamfered cam bearings
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Engine assembly
OHV assembly
• Check cam for straightness• Check cam fit in bearings & scrape as needed
Cam must rotate freely• Blow all passages clear
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Engine assembly
OHV assembly
• Grease cam to protect lobes & install cam
• Install oil galley plugs with sealer on outer edges
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Engine assembly
OHV assembly
• Install rear main seal (two piece seal)
• Install main bearings• Install crankshaft & check clearance
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Engine assembly
OHV assembly
• Oil all bearings & position thrust main cap
• Torque all main caps• Check crankshaft endplay
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Engine assembly
OHV assembly
• Install thrust plate & timing set
• Check camshaft endplay
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Engine assembly
OHV assembly
• Install piston assemblies
• Loctite & torque rod nuts
• Check rod side clearance
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Engine assembly
OHV assembly
• Install oil pump & drive shaft• Verify cam timing at split overlap
• Install timing cover
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Engine assembly
OHV assembly
• Install oil pan• Torque heads onto block
• Install rocker arms & pushrods• Adjust valves & test
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Engine assembly
OHC assembly differences
• Balance shaft bearings• Crank & cam must be set to TDC before installation• Some timing covers are installed before head or pan• Timing belts and covers are installed last
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Engine assembly
Sealing crankshafts
• Bearing clearance must not be excessive• Seal surfaces must be concentric with journals
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Engine assembly
Sealing crankshafts
• Seals should be within .005” TIR of crank centerline
• Poor seal concentricity with main caps not centered
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Engine assembly
Sealing crankshafts
• Seal surfaces must not have grooves
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Engine assembly
Sealing crankshafts
• Rope type rear main seals• Coated with dry lubricant• Do not oil • Fitted with round stock, same size as seal surface
on crankshaft
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Engine assembly
Sealing crankshafts• Lip seal rear main
Sealer on outer edgeOil on sealing surfaceThin coat of sealer at rear of parting line
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Engine assembly
Sealing crankshafts• Side seals on rear main
Installed with nail or soaked in oil
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Engine assembly
Valve timing• Check service manual for timing marks• Confirm by checking split overlap• Dual pattern cams don’t have equal lift & duration
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Engine assembly
Valve timing• Valve timing can be adjusted with keys & bushings
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Engine assembly
Pistons & rings• End gap .003” per inch of cylinder bore• Hypereutectic pistons use twice as much• End gap is increased by filing• End gap increases .003” for each .001” bore increase
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Engine assembly
Pistons & rings• Oil control expander, then rails
Stagger end gaps• Lower compression ring, then top
Stagger end gapsOil grooves & check for rotation
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Engine assembly
Piston types• Cast aluminum – OEM pistons• Forged aluminum – Stronger & better heat dissipation • Hypereutectic – High silicon content
LighterGood wear characteristicsTighter clearances due to low expansion rateRequires more ring end gap
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Engine assembly
Piston skirts• Slipper skirts – Cam ground
Clearance for counterweightsSteel struts help piston expand with pin
• Barrel shaped skirt– Largest diameter is in the center
• Full skirt– Used in longer stroke engines
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Engine assembly
Before attaching heads to blocks• Surfaces clean and flat
• Alignment dowels installed
• Threads clean • Sharp edges de-burred
• Check gasket direction Do not use sealer on coated gaskets
• Look up torque specs & sequence
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Engine assembly
Attaching heads to blocks
• Torque in sequence in 3 steps• Threads lubricated with oil or sealer
• TTY bolts may need to be replaced
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Engine assembly
Rocker arms
• Check rocker shafts for correct direction• Check for correct offset of rocker arms
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Engine assembly
Valve adjustment
Piston at TDC, compression• Non-hydraulic valve trains
Adjust valves that are closed & rotate engine
• Adjustable hydraulic valve trainsZero lash plus pre-loadCollapse lifter and set clearance
• Non-adjustable hydraulic valve trains
Torque to specs
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Engine assembly
Pre-oiling
Install lifters• Push rod engine
Rotate oil pump with speed handle
• Crank driven oil pumpsPre-lubricator used to pre-oil engines
• Assemble oil pump with grease for priming
• Crank engine with no spark plugs, fuel, or ignition
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Engine assembly
Run-in stand
• Oil pressure & circulation• Compression• Noises• Gaskets & seals • Lifter rotation
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THANK YOU