Dev kumar mahato assembly 2
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The document provides instructions for assembling an engine. It discusses cleaning and preparing engine components before assembly, installing core plugs and seals, assembling cylinder heads and installing valves, installing pistons and rings, attaching the heads to the block, installing rocker arms and adjusting valves, pre-oiling the engine, and testing the engine on a run-in stand. The document provides detailed steps and considerations for properly assembling the various engine components.
Dev kumar mahato assembly 2
- 1. Engine assembly NAME=DEV KUMAR MAHATO U.ROLL. NO.= 7626147 COLLEGE ROLL NO.=1240775
- 2. Engine assembly Before final cleaning • Remove all sharp edges created by machining • Clean all internal & external threads Combustion chamber Crankshaft oil holes Top & bottom of cylinders Oil pump gears Chamfer top of bolt holes Use tap or die for restoring threads Copyright 2003 Gary Lewis – Dave Capitolo
- 3. 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
- 4. Engine assembly Final cleaning • Only after all machining is done • Use detergent hot tank • Insufficient cleaning results in . . . Piston ring wear Bearing wear Valve stem wear
- 5. Engine assembly Final cleaning • Coat cylinders & decks with clean oil to prevent rust • Coat valves, seats, & decks with clean oil
- 6. 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
- 7. 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
- 8. 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
- 9. Engine assembly Chemical sealers • Sometimes used in place of gaskets • Silicone sealers (RTV) are flexible & temp resistant • Anaerobic sealers – Absence of air
- 10. Engine assembly Head gaskets • Metal-asbestos replaced with ceramic laminate • Composite core copper Good compressibility, low compression, 60AA • Composite core steel Heat resistant, high compression, 60AA • Coated gaskets Resin, polymer, better sealing of fluids • MLS (Multi layer steel) For dissimilar metals, 15-20AA
- 11. Engine assembly Head gaskets • Stainless steel face On one side for high cylinder head temps, GM diesels • Embossed steel Improved heat transfer, ridges provide crush for sealing, high compression, 30-50AA • No-retorque Polymer coated, printed with silicone for low clamping force areas
- 12. Engine assembly Gaskets • Cork used on valve covers, lifter covers, oil pans Stretches & shrinks • Synthetic rubber Compressible, does not wick, resists heat
- 13. Engine assembly Crankshaft seals • Rope type seals must be fitted • Lip type seals Lips face the oil • Nitril & neoprene are common • Viton withstands loads & heat
- 14. Engine assembly OHV assembly • Only after sub-assemblies have been inspected • Install core plugs • Install chamfered cam bearings
- 15. Engine assembly OHV assembly • Check cam for straightness • Check cam fit in bearings & scrape as needed Cam must rotate freely • Blow all passages clear
- 16. Engine assembly OHV assembly • Grease cam to protect lobes & install cam • Install oil galley plugs with sealer on outer edges
- 17. Engine assembly OHV assembly • Install rear main seal (two piece seal) • Install main bearings • Install crankshaft & check clearance
- 18. Engine assembly OHV assembly • Oil all bearings & position thrust main cap • Torque all main caps • Check crankshaft endplay
- 19. Engine assembly OHV assembly • Install thrust plate & timing set • Check camshaft endplay
- 20. Engine assembly OHV assembly • Install piston assemblies • Loctite & torque rod nuts • Check rod side clearance
- 21. Engine assembly OHV assembly • Install oil pump & drive shaft • Verify cam timing at split overlap • Install timing cover
- 22. Engine assembly OHV assembly • Install oil pan • Torque heads onto block • Install rocker arms & pushrods • Adjust valves & test
- 23. 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
- 24. Engine assembly Sealing crankshafts • Bearing clearance must not be excessive • Seal surfaces must be concentric with journals
- 25. Engine assembly Sealing crankshafts • Seals should be within .005” TIR of crank centerline • Poor seal concentricity with main caps not centered
- 26. Engine assembly Sealing crankshafts • Seal surfaces must not have grooves
- 27. 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
- 28. Engine assembly Sealing crankshafts • Lip seal rear main Sealer on outer edge Oil on sealing surface Thin coat of sealer at rear of parting line
- 29. Engine assembly Sealing crankshafts • Side seals on rear main Installed with nail or soaked in oil
- 30. Engine assembly Valve timing • Check service manual for timing marks • Confirm by checking split overlap • Dual pattern cams don’t have equal lift & duration
- 31. Engine assembly Valve timing • Valve timing can be adjusted with keys & bushings
- 32. 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
- 33. Engine assembly Pistons & rings • Oil control expander, then rails Stagger end gaps • Lower compression ring, then top Stagger end gaps Oil grooves & check for rotation
- 34. Engine assembly Piston types • Cast aluminum – OEM pistons • Forged aluminum – Stronger & better heat dissipation • Hypereutectic – High silicon content Lighter Good wear characteristics Tighter clearances due to low expansion rate Requires more ring end gap
- 35. Engine assembly Piston skirts • Slipper skirts – Cam ground Clearance for counterweights Steel struts help piston expand with pin • Barrel shaped skirt– Largest diameter is in the center • Full skirt– Used in longer stroke engines
- 36. 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
- 37. 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
- 38. Engine assembly Rocker arms • Check rocker shafts for correct direction • Check for correct offset of rocker arms
- 39. Engine assembly Valve adjustment Piston at TDC, compression • Non-hydraulic valve trains Adjust valves that are closed & rotate engine • Adjustable hydraulic valve trains Zero lash plus pre-load Collapse lifter and set clearance • Non-adjustable hydraulic valve trains Torque to specs
- 40. Engine assembly Pre-oiling Install lifters • Push rod engine Rotate oil pump with speed handle • Crank driven oil pumps Pre-lubricator used to pre-oil engines • Assemble oil pump with grease for priming • Crank engine with no spark plugs, fuel, or ignition
- 41. Engine assembly Run-in stand • Oil pressure & circulation • Compression • Noises • Gaskets & seals • Lifter rotation
- 42. THANK YOU