Friday, November 18, 2011

Car Engine Overhaul Tips?


If you need dis-assembly or replacement instructions for any other auto/car part, or you want to ask question related to your car/truck jeep problem then please leave the comment with your details, so I can provide you the required instructions and solutions.

The procedure is as follows :---

Most engine overhaul procedures are fairly standard. In addition to specific parts replacement procedures and specifications for your individual engine, this section is also a guide to acceptable rebuilding procedures. Examples of standard rebuilding practice are given and should be used along with specific details concerning your particular engine.
Competent and accurate machine shop services will ensure maximum performance, reliability and engine life. In most instances it is more profitable for the do-it-yourself mechanic to remove, clean and inspect the component, buy the necessary parts and deliver these to a shop for actual machine work.
Much of the assembly work (crankshaft, bearings, piston rods, and other components) is well within the scope of the do-it-yourself mechanic's tools and abilities. You will have to decide for yourself the depth of involvement you desire in an engine repair or rebuild.

TOOLS



The tools required for an engine overhaul or parts replacement will depend on the depth of your involvement. With a few exceptions, they will be the tools found in a mechanic's tool kit (see General Information and Maintenance of this guide). More in-depth work will require some or all of the following:


A dial indicator (reading in thousandths) mounted on a universal base
Micrometers and telescope gauges
Jaw and screw-type pullers
Scraper
Valve spring compressor
Ring groove cleaner
Piston ring expander and compressor
Ridge reamer
Cylinder hone or glaze breaker
Plastigage®
Engine stand

The use of most of these tools is illustrated in this section. Many can be rented for a one-time use from a local parts jobber or tool supply house specializing in automotive work.
Occasionally, the use of special tools is called for. See the information on Special Tools and the Safety Notice in the front of this guide before substituting another tool.

OVERHAUL TIPS



Aluminum has become extremely popular for use in engines, due to its low weight. Observe the following precautions when handling aluminum parts:


Never hot tank aluminum parts (the caustic hot tank solution will eat the aluminum.
Remove all aluminum parts (identification tag, etc.) from engine parts prior to the tanking.
Always coat threads lightly with engine oil or anti-seize compounds before installation, to prevent seizure.
Never over tighten bolts or spark plugs especially in aluminum threads.

When assembling the engine, any parts that will be exposed to frictional contact must be prelubed to provide lubrication at initial start-up. Any product specifically formulated for this purpose can be used, but engine oil is not recommended as a prelube in most cases.
When semi-permanent (locked, but removable) installation of bolts or nuts is desired, threads should be cleaned and coated with Loctite(r) or another similar, commercial non-hardening sealant.

CLEANING



Before the engine and its components are inspected, they must be thoroughly cleaned. You will need to remove any engine varnish, oil sludge and/or carbon deposits from all of the components to insure an accurate inspection. A crack in the engine block or cylinder head can easily become overlooked if hidden by a layer of sludge or carbon.
See Figure 1
Click image to see an enlarged view
Fig. Fig. 1: Use a gasket scraper to remove the old gasket material from the mating surfaces
Most of the cleaning process can be carried out with common hand tools and readily available solvents or solutions. Carbon deposits can be chipped away using a hammer and a hard wooden chisel. Old gasket material and varnish or sludge can usually be removed using a scraper and/or cleaning solvent. Extremely stubborn deposits may require the use of a power drill with a wire brush. If using a wire brush, use extreme care around any critical machined surfaces (such as the gasket surfaces, bearing saddles, cylinder bores, etc.). Use of a wire brush is NOT RECOMMENDED on any aluminum components. Always follow any safety recommendations given by the manufacturer of the tool and/or solvent. You should always wear eye protection during any cleaning process involving scraping, chipping or spraying of solvents.
An alternative to the mess and hassle of cleaning the parts yourself is to drop them off at a local garage or machine shop. They will, more than likely, have the necessary equipment to properly clean all of the parts for a nominal fee.

CAUTION
Always wear eye protection during any cleaning process involving scraping, chipping or spraying of solvents. See Figure 2



Click image to see an enlarged view
Fig. Fig. 2: Use a ring expander tool to remove the piston rings
Remove any oil galley plugs, freeze plugs and/or pressed-in bearings and carefully wash and degrease all of the engine components including the fasteners and bolts. Small parts such as the valves, springs, etc., should be placed in a metal basket and allowed to soak. Use pipe cleaner type brushes, and clean all passageways in the components. Use a ring expander and remove the rings from the pistons. Clean the piston ring grooves with a special tool or a piece of broken ring. Scrape the carbon off of the top of the piston. You should never use a wire brush on the pistons. After preparing all of the piston assemblies in this manner, wash and degrease them again.
See Figures 3 and 4
Click image to see an enlarged view
Fig. Fig. 3: Clean the piston ring grooves using a ring groove cleaner tool, or ...


Click image to see an enlarged view
Fig. Fig. 4: ... use a piece of an old ring to clean the grooves. Be careful, the ring can be quite sharp

WARNING
Use extreme care when cleaning around the cylinder head valve seats. A mistake or slip may cost you a new seat.

When cleaning the cylinder head, remove carbon from the combustion chamber with the valves installed. This will avoid damaging the valve seats.

REPAIRING DAMAGED THREADS



See Figures 5 through 9
Click image to see an enlarged view
Fig. Fig. 5: Damaged bolt hole threads can be replaced with thread repair inserts


Click image to see an enlarged view
Fig. Fig. 6: Standard thread repair insert (left), and spark plug thread insert


Click image to see an enlarged view
Fig. Fig. 7: Drill out the damaged threads with the specified size bit. Be sure to drill completely through the hole or to the bottom of a blind hole


Click image to see an enlarged view
Fig. Fig. 8: Using the kit, tap the hole in order to receive the thread insert. Keep the tap well oiled and back it out frequently to avoid clogging the threads


Click image to see an enlarged view
Fig. Fig. 9: Screw the insert onto the installer tool until the tang engages the slot. Thread the insert into the hole until it is 1/4 - 1/2 turn below the top surface, then remove the tool and break off the tang using a punch
Several methods of repairing damaged threads are available. Heli Coil(r) (shown here), Keenserts(r) and Microdot(r) are among the most widely used. All involve basically the same principle drilling out stripped threads, tapping the hole and installing a prewound insert making welding, plugging and oversize fasteners unnecessary.
Two types of thread repair inserts are usually supplied: a standard type for most inch coarse, inch fine, metric course and metric fine thread sizes and a spark lug type to fit most spark plug port sizes. Consult the individual tool manufacturer's catalog to determine exact applications. Typical thread repair kits will contain a selection of prewound threaded inserts, a tap (corresponding to the outside diameter threads of the insert) and an installation tool. Spark plug inserts usually differ because they require a tap equipped with pilot threads and a combined reamer/tap section. Most manufacturers also supply blister-packed thread repair inserts separately in addition to a master kit containing a variety of taps and inserts plus installation tools.
Before attempting to repair a threaded hole, remove any snapped, broken or damaged bolts or studs. Penetrating oil can be used to free frozen threads. The offending item can usually be removed with locking pliers or using a screw/stud extractor. After the hole is clear, the thread can be repaired, as shown in the series of accompanying illustrations and in the kit manufacturer's instructions.
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For more car related problem troubleshooting:---

This are the sections, you can go through and click the link to read its troubleshooting.

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The car will not start?

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Car will not crank?


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Car has no spark?


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How to troubleshoot car battery?

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How to test starter solenoid?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html

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How to test cars starter?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html

How to replace starter in car?



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car will turn over but will not start?



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Car wont start?


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The Brake Indicator Light Stays On dash of car?

The ABS and Traction Control Lights stays ON dash of car?


Check Engine Light On car?

 -------------------------

How to replace Interior Lights on car?

Car lights not working, even after replacing the bulb/lamp?

Click this link below:--
 ---------------

How to replace head lights on car?

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How to replace Parking, turn, and Brake Lights on car?

How to replace power window motor in car?

How to test relays on car?

 -----------------------------

How to troubleshoot Engine Misfires?

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The spark plug firing order for car?

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Where is the Thermostat located in car?

How to recharge AC on Auto/Truck/car?

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How to trouble shoot speedometer?
To Order car parts online:--To get heavy discount on car parts .Click this link below:----

How to Replace Coil Springs?

How to Replace an Oil Pan Gasket?


How to Replace a Fuel Injector


How to Replace a C.O.P. Type Ignition Coil?

How to Replace a Fuel Pressure Regulator?

How to Replace a Fuel Pump?

How to Replace a Rear Lift Gate Locking Mechanism?


How to Clean a Fuel System

How to Replace an Ignition Coil


How to Replace a Windshield



How to Replace a Mass Air Flow Sensor


How to Replace a Rear Distance Sensor

How to Replace a Muffler


How to Replace an Engine


How to Replace an Intake Manifold Gasket



How to Replace an Oil Pump


How to Lubricate a Brake Pedal Linkage ?

How to Replace a Windshield Wiper Motor



How to Replace a Distributor Cap


How to Replace a Door Weather Stripping


How to Replace a Freeze Plug


How to Replace a Head Gasket

How to Replace a Heater Core

How to Replace Spark Plugs?


How to Replace a Rear Axle Bearing?

How to Replace a Front Bumper Cover



How to Replace a Manual Transmission



How to Replace a Headlight Bulb



How to Replace a Headlight Switch



How to Replace Windshield Wiper Blades


How to Replace a Cooling Fan


How to Replace a Catalytic Converter


How to Replace an Engine Mount



How to Replace a Fog Light Assembly



How to Change Engine Oil and Filter



How to Replace a Power Seat Switch


How to Replace a Rear Main Seal


How to Repair a Defroster Grid



How to Replace an AWD Transfer Case


How to Replace a Plastic License Plate Bracket?

How to Replace a Power Seat Motor


How to Replace Power Steering Fluid


How to Replace a Power Window Switch



How to Replace a Quarter Glass Panel?


How to Pressure Test a Radiator and Cap


How to Replace a Radiator


How to Repair a Hood.

How to Replace an Energy Absorber


How to Replace Heater Core Hoses


How to Replace a Thermostat.


How to Rotate Tires.

How to Replace Wheel Lug Nuts


How to Replace a Tire Valve Stem



How to Change a Flat Tire



How to Replace Leaf Springs


How to Replace a Heater Control Valve


How to Replace Transmission Cooler Lines


How to Replace an Ignition Control Unit


How to Replace a Brake Hose


How to Replace a Transfer Case Rear Output Seal


How to Replace a Seat Belt and Seatbelt Retractor


How to Replace a Power Steering Rack


How to Bleed Brakes with a Tool


How to Replace a Tail Light Bulb


How to Check Automatic Transmission Fluid Level



How to Change Automatic Transmission Fluid and Filter


How to Replace Vacuum Hoses



How to Replace an Air Intake Boot



How to Replace a Valve Cover Gasket


How to Replace a Water Pump


How to Replace a Windshield Wiper Switch



How to Replace Window Run Channel Seals


How to Replace a Window Regulator



How to Balance a Tire and Wheel




How to Replace a Window Motor


How to Adjust a Hood Release Latch?


How to Replace a Radiator Support


How to Replace a Rear Pinion Seal.


How to Replace Battery Cables




How to Replace a Proportioning Valve



How to Replace an Upper Radiator Hose



How to Replace a Lower Radiator Hose


How to Replace a Timing Belt?

How to Check for Loose or Worn Suspension 



How to Check for Loose Steering System

How to Replace an Oil Pressure Switch (Sensor)


How to Replace a Fender Liner or Splash Shield



How to Replace a Hood Insulator


How to Replace a Rear Differential.

How to Repair a Hood Hinge


How to Replace a Brake Pedal Return Spring



How to Replace a Door Shell.

How to Replace a Transfer Case Front Output Seal


How to Replace a Hood Latch/Lock Assembly


How to Replace a Lift Gate Strut

How to Replace Mud Flaps (Mud Guards)



How to Check Differential Oil Leaks and Replace Oil.


How to Replace a Mirror

How to Replace a Transfer Case Shift Linkage



How to Replace a Transmission Mount



How to Replace a U-Joint


How to Replace a Washer Tank


How to Replace an A/C Line or Hose


How to Replace a Heater and A/C Blower Motor


How to Replace an ABS Control Unit



How to Perform a Brake Adjustment




How to Replace an Alternator Belt




How to Replace an Emblem


How to Replace an Exhaust Manifold Gasket


How to Replace a Tail Pipe


How to Replace Shock Absorbers


How to Replace a Strut Assembly



How to Replace a Driveshaft



How to Replace a Wheel Cylinder


How to Replace a Hood


How to Replace a Brake Disc (Rotor)


How to Replace a Metal License Plate Bracket



How to Replace a Power Steering Pump


How to Perform a Basic Engine Tune-Up


How to Perform a Basic Engine Tune Up-Oil Change



How to Perform a Basic Engine Tune Up-Spark Plug and Wire Change

How to Replace a Distributor Cap and Rotor ?



How to Repair a Valance


How to Replace a Turn Signal Switch


How to Replace a Plastic Bumper Cover


How to Replace a Parking Brake Cable


How to Replace Windshield Wiper Blade Refills



How to Replace a Corner Light


How to Replace a Bumper Bracket or Side Support


How to Replace a Washer Pump.

How to Replace a Grille


How to Replace a Locking Hub


How to Replace a Fender


How to Replace a Power Steering Hose


How to Replace a Tailgate


How to Replace a Soft Top


How to Replace a Carburetor

­

How to Replace a Bumper Trim



How to Replace Trunk Strut


How to Replace a Front End Cover


How to Replace a Front Pipe


How to Replace an Antenna Mast


How to Replace a Side Marker Light Assembly


How to Install a Carpet on car?

How to Replace a Spoiler


How to Replace a Mirror Glass on car?



How to Replace a Step Bumper?


How to Replace a Door Lock


How to Replace a Throttle Body


How to Replace a Throttle Position Sensor


How to Replace a Grille Insert


How to Replace a Fan Shroud Assembly



How to Replace an Engine Splash Shield



How to Replace a Turn Signal Light Assembly


How to Replace a Headlight Assembly


How to Replace a Park Light Assembly

How to Replace an Expansion Tank



How to Replace an Exhaust System


How to Replace a Fender Trim


How to Replace a Headlight Door


How to Replace a Fan Shroud


How to Replace a Harmonic Balancer


How to Replace a Header Panel


How to Replace a Fuel Tank


How to Replace a Fuel Tank Cap


How to Replace a Distributor


How to Replace an EGR Valve


How to Replace an Oxygen Sensor


How to Replace an Ignition Wire Set


How to Replace a Tail Light


How to Replace a Door Handle


How to Replace a Hood Strut


How to Replace Tail Light Assembly


How to Replace a Front Bumper


How to Replace a Fuel Pump Assembly


How to Replace an Axle Assembly


How to Replace a Tailgate Handle


How to Replace a Wheel Hub Assembly


How to Replace a Control Arm


How to Replace a Window Regulator with Motor


How to Replace a Headlight



How to Check the Brake Fluid Level

How to Replace a Parking Brake Switch


How to Replace a Blower Motor Resistor


How to replace frost plug on car?

Horn stopped working?


How to clean egr valve on Isuzu Amigo?


Cruise control stopped working?

Car is stuck in park and the shift will not move?

How to change the outer door weather strip?


Car slows down when it gets hotter?


Warning lights on and speedometer died?



Car won't rev past 1900 rpms?





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