Emergency Care and Transportation of the Sick and Injured ...



Chapter 11

Engine Removal and Replacement

NATEF Tasks

Engine Repair

General

• Inspect, remove, and replace engine mounts. AST, MAST (pp 291–294)

Knowledge Objectives

1. Describe the tools used to remove an engine. (pp 284–285)

2. Explain the steps involved in safely preparing to remove and reinstall an engine. (p 285)

3. Describe the engine removal process from the top side of the engine. (pp 286–287)

4. Describe the components involved in front accessories disconnection. (pp 287–289)

5. Describe the components involved in underside disconnection. (pp 289–291)

Skills Objectives

1. Remove an engine. (pp 291–292)

2. Reinstall an engine. (pp 292–293)

3. Perform prestart engine checks. (pp 293–294)

4. Restore the vehicle to running condition. (p 294)

Readings and Preparation

Review all instructional materials, including Chapter 11 of Fundamentals of Automotive Technology: Principles and Practice and all related presentation support materials.

Support Materials

• Lecture PowerPoint presentation

• Skill Drill PowerPoint presentations

Direct students to visit the companion website to Fundamentals of Automotive Technology: Principles and Practice at CW/Fundamentals.

Pre-Lecture

You are the Automotive Technician

“You are the Automotive Technician” is a progressive case study that encourages critical-thinking skills.

Instructor Directions

Direct students to read the “You are the Automotive Technician” scenario found at the beginning of Chapter 11.

• You may wish to assign students to a partner or a group. Direct them to review the discussion questions at the end of the scenario and prepare a response to each question. Facilitate a class dialogue centered on the discussion questions.

• You may also use this as an individual activity and ask students to turn in their comments on a separate piece of paper.

Lecture

I. Introduction

A. An engine typically needs to be removed for repair or replacement once a major failure has been diagnosed.

1. If well maintained, an engine should last 200,000 miles (322,000 kilometers [km]) or more.

a. Abuse or defective components can shorten life of engine.

B. Engine will let you know if something is wrong.

1. Excessive noise.

2. Might not crank over.

3. Dash lights indicate low oil pressure, high operating temperature, or malfunctioning emission controls.

a. Malfunctioning indicator light (MIL): dash light that indicates presence of diagnostic trouble code or malfunction, such as dead engine cylinders

C. Major mistake made my technicians is rushing to get job done.

1. Technicians must be organized, careful, and methodical.

D. First step is to reference manufacturer’s service information.

1. Follow steps listed step by step.

II. Engine Removal Tools

A. Special service tools

B. Vehicle lift

C. Engine hoist

1. Used if engine pulled from top of engine compartment

2. Must be rated for capacity you are lifting

D. Engine stand

E. Jacks

F. General shop hand tools

G. Scan tool

1. Used on all but vintage vehicles

a. Check and clear trouble codes.

b. Relieve pressure from fuel systems.

c. Monitor engine and transmission systems after starting replacement engine.

H. Strong chain

1. Make sure chain can exceed weight capacity it will support.

I. Scissor jack

1. Required if engine being removed by lowering it from underneath vehicle

a. Recommended for many front-wheel drive vehicles

III. Preparation and Safety

A. There are many engine installation configurations, all with similar engine removal procedures.

1. Front-wheel drive

2. Rear-wheel drive

3. All-wheel drive

B. Most engines in rear-wheel drive vehicles are best removed from top of engine compartment.

1. Engine can be separated from transmission and removed by itself.

2. Engine and transmission can be removed as a unit.

C. Most engines in front-wheel vehicles are best removed from top or bottom of engine compartment.

1. If removed from bottom, engine and transaxle are usually removed as unit attached to engine cradle.

D. Always respect and implement shop safety standards and regulations.

IV. Topside Disconnection

A. First step in engine removal is to remove hood.

1. Greater access to engine

2. Great visibility

B. Scribe or mark the hood bracket where bolts attach hood to hinge before removing hood.

1. You’ll have exact placement when time to reinstall hood.

C. Disconnect everything within reach from top of engine.

1. Disable electrical system by disconnecting battery.

D. Most vehicles are fuel injected.

1. Typically, a fuel injection supply line stays under pressure even when the engine is

not running. You’ll need to relieve pressure on fuel system before disconnecting fuel lines.

a. If vehicle is in running condition:

i. Remove fuel pump fuse while engine is running until out of fuel.

b. If fuel-injected vehicle is not running:

i. Install a fuel pressure gauge and relieve the pressure by venting the extra fuel into a plastic bottle.

ii. Once the fuel pressure has been relieved, you can disconnect the fuel line.

2. For most fuel-injected vehicles, you will need a fuel disconnect tool.

3. Block off and seal fuel supply line from fuel tank.

a. Wedge tapered punch inside line or tape over end of line with duct tape.

E. Most modern vehicles have 10 or more computers monitoring and controlling all systems in vehicle.

1. Disconnecting battery before disconnecting any other component from engine will help prevent damage.

2. Be sure to unlock any necessary codes before disconnecting battery.

3. Negative terminal of battery must be removed first.

a. Already grounded and considered safe

4. Do not lay tools on battery as positive and negative posts of battery could connect, causing battery to explode.

F. Be methodical and careful when disconnecting electrical wires and connectors.

1. Look closely at electrical wire harnesses to evaluate best area to disconnect.

2. Take photos of placements before you disconnect.

a. For late-model vehicles, the electrical plug ends are not interchangeable; pictures will help you remember the general locations.

V. Front Accessories Disconnection

A. The next step in engine removal is to remove radiator and accessories.

1. This includes air-conditioning compressor, power steering pump, related mounting brackets and components.

2. Determine whether air-conditioning or power steering systems need to be opened for engine removal.

a. If air-conditioning system needs to be opened, refrigerant needs to be removed and stored by properly trained technician.

b. If power steering circuit needs to be opened, fluid must first be drained.

B. Always make sure engine is cool before removing radiator cap.

1. Typical boiling point for automotive coolant is 223°F (106°C).

2. Drain valve or plug located at bottom of radiator.

a. If not, disconnect lower radiator hose, place drain pan underneath valve, and open valve.

b. If no valve, place pan under lower radiator hose.

3. Disconnect lower radiator hose until coolant has been drained, then disconnect upper radiator hose.

a. Rear-wheel drive: Disconnect fan shroud, unbolt radiator, and remove.

b. Front-wheel drive: Disconnect electric fan, and determine if enough room to remove radiator without removing fans.

i. If not, remove fans, unbolt radiator, and remove radiator.

C. Accessory components such as air-conditioning compressors and power steering pumps are mounted to engine with brackets.

1. Also used to adjust mounted components

2. Keep as many of the components and attachment bolts together as possible when removing.

3. Take off only the brackets that are necessary to remove the engine.

D. When removing air-conditioning system, keep system sealed.

1. Use mechanics wire to secure compressor and hoses up and out of way.

2. Best if you can leave all air-conditioning lines intact and use mechanics wire to hold components off of engine.

E. When removing power steering pump, take it off the bracket and wire it out of way.

1. Disconnecting hydraulic line usually not necessary.

VI. Underside Disconnection

A. Best use of your time:

1. Take your time.

2. Work carefully and methodically.

3. Review manufacturer’s information prior to disconnection.

B. Drain engine oil, transmission/transaxle fluid, and the cooling system.

1. Look for related units that might need to be drained.

a. Power steering fluid

C. Today’s exhaust systems are more complex than they used to be.

1. Three or four oxygen sensors

2. Catalytic converter

3. Turbocharger driven by exhaust gases

4. Light-duty diesel-powered vehicles include particulate filters

D. First identify oxygen sensors that need to be removed/disconnected for exhaust removal.

1. Disconnect sensors.

2. Check exhaust pipe and component routing.

a. Make certain exhaust pipes won’t restrict engine removal.

3. Disconnect exhaust pipe from exhaust header or manifold.

E. Starter needs to be removed before engine is removed.

1. Normally located where engine and transmission/transaxle are mounted together

a. Bell housing

2. Understand that positive battery cable connects to terminal on starter.

a. Imperative that battery is disconnected before removing cable and wires from starter

3. Disconnect starter electrical wires and mark where they go.

4. Remove starter bolts and lower starter from engine or bell housing.

F. To access torque converter bolts on rear- and front-wheel drive, remove inspection cover on bell housing.

1. Front-wheel drive: Unbolt subframe or cradle if bottom removal.

a. Subframe is a mount attached to vehicle used to support engine and transaxle assembly.

2. Turn flex plate so one of torque converter bolts is accessible.

3. Push torque converter into bell housing so it doesn’t fall out during engine removal.

G. If engine is removed from bottom using subframe scissor jack, do not disconnect transaxle at this time.

H. If engine is removed from top without transmission/transaxle, unbolt transmission/transaxle but don’t try to separate transmission/transaxle from engine at this time.

I. Manual transmission, rear-wheel drive: Determine if it can be separated from bell housing or if bell housing is integral with transmission case.

1. Determine if bell housing should be unbolted from engine or transmission.

2. Unbolt transmission or bell housing or transaxle but do not separate the two.

VII. Engine Removal

A. It is always helpful and much safer to have two other people assisting you during engine removal.

1. One person operating hoist while two others guide engine as it is lifted or lowered from vehicle

2. Do final check for anything that needs to be disconnected that might have been missed.

B. Using a chain, connect engine to proper lifting points.

1. Make sure chain and bolts are rated for engine weight.

2. Use at least grade 5 bolts screwed in at least five full turns.

C. Once engine is out, set it on floor with tension in chain.

D. Mount engine to engine stand.

1. Use at least grade 5 bolts screwed in at least five full turns.

E. To position subframe scissor jack under engine and subframe, refer to vehicle’s shop service information.

F. When scissor jack is in place, strap engine and transaxle to scissor jack.

1. Remove front brake calipers and secure to vehicle or remove front brake lines to calipers.

2. Remove cradle bolts and lower subframe scissor jack.

3. Remove engine from transaxle by disconnecting torque converter nuts/bolts first.

4. Secure chain of engine hoist/boom lift to engine.

5. Remove transaxle bolts and engine motor mounts.

6. Raise engine an inch to separate engine from transaxle while starting to raise engine.

7. Lower engine to floor then mount to engine stand.

8. Drain any remaining oil and remove coolant soft plugs.

VIII. Engine Installation

A. Have assistants just as with engine removal.

B. First organize work site.

1. Make sure it’s clean and clear of obstructions.

2. Arrange bolts and engine mounts needed.

3. Lay out tools needed.

C. Reverse removal process to install engine, with a few additional steps.

1. For automatic transmissions, consider changing front transmission seal while torque converter removed.

a. Fill torque converter with proper transmission fluid.

2. For manual transmissions, clutch discs need to be aligned with clutch pilot hole.

a. Align clutch disc and install pressure plate.

b. Sometimes the splined input shaft must be turned to align with clutch disc splines.

D. After transmission is bolted to engine, engine needs to be mounted to vehicle frame or cradle.

1. Attach motor mounts that connect engine to frame or mounting platform.

2. Lower engine, aligning motor mounts.

3. Tighten motor mounts and reinstall all parts and components in reverse order of disassembly.

IX. Engine Start-up

A. Start-up is a critical time for engine operation and longevity.

1. Make sure all fluid levels are at correct level and no leaks.

2. Check that battery terminal connected and battery charged.

3. Make sure fuel is supplied to injection system by turning key to run position.

4. If ignition timing is adjustable, set close enough to start and hook up timing light to make adjustment when engine first starts.

a. Most vehicles made post-1980 have computers to control timing.

5. Check auxiliary components for proper installation.

6. Check serpentine belt and pulleys for proper installation.

7. Check that electrical connectors and vacuum hoses are properly connected.

8. Connect exhaust removal hose to exhaust pipe.

9. Verify brake pedal is not spongy.

10. Crank engine for 10 seconds or less.

a. Some new break-in procedures require engine to run 20 to 30 minutes for proper lubrication.

b. Ensure piston rings are seated properly and camshaft and other components are not damaged.

B. After engine is started, connect a diagnostic scan tool to the data link connector (DLC) and check for diagnostic trouble codes (DTCs).

1. Check for leaks, fluid levels, and missing components.

2. Drive for 30 minutes without exceeding 50 mph.

X. Summary

A. Before the engine fails, there are usually warning signs such as dash warning lights indicating low oil pressure, high operating temperature, or a malfunctioning emission control system.

B. The first step in performing an engine removal installation task is to reference the appropriate service information, preferably the manufacturer’s service information.

C. The tools needed to remove and replace an engine include special service tools, a vehicle lift, an engine hoist, jacks, and general shop hand tools.

D. Make sure the engine hoist is rated for the weight capacity you will be lifting.

E. Once the engine has been removed from the vehicle, use an engine stand to support the engine while taking it apart.

F. There are many engine installation configurations. They include front-wheel drive, rear-wheel drive, and all-wheel drive designs.

G. Engine removal and installation can be dangerous; therefore, it is important to put safety first in each step of the process.

H. Modern vehicles typically have 10 or more computers monitoring and controlling virtually every operational system of the vehicle.

I. Disconnect the battery before disconnecting any other component from the engine.

J. When disconnecting the battery, remove the negative terminal from the battery first.

K. Typically, a fuel injection supply line stays under pressure even when the engine is not running. Therefore, you will need to relieve the pressure on the fuel system before disconnecting the fuel line.

L. If an air-conditioning system needs to be opened, the refrigerant will need to be removed and stored using the appropriate recycling machine.

M. The boiling point of engine coolant is increased by the coolant properties, and the cooling system pressure is maintained by the pressure cap.

N. Make sure the engine is cool before draining the radiator.

O. Air-conditioning compressors and power steering pumps are examples of accessory components that are mounted to the engine.

P. Currently produced vehicles could have three or four oxygen sensors, a catalytic converter, and a turbocharger driven by the exhaust.

Q. The starter motor is normally located where the engine and the transmission are mounted together.

R. When removing an engine, it is always helpful to have two other people assisting you.

S. Time spent organizing the work site will ensure a safe and smooth engine installation.

T. When reinstalling the torque converter, push in and turn the torque converter, making sure three distinct clunks are felt.

U. Engine start-up after installation is a critical time for engine operation and longevity.

V. To ensure that the piston rings are seated properly and that the camshaft and other internal components are not damaged, it is important to follow appropriate break-in procedures.

W. An important task after you have started the engine is to connect a diagnostic scanner to the data link connector (DLC) and check for diagnostic trouble codes (DTCs).

Post-Lecture

This section contains various student-centered end-of-chapter activities designed as enhancements to the instructor’s presentation. As time permits, these activities may be presented in class. They are also designed to be used as homework activities.

ASE-Type Questions

This activity is designed to assist the student in gaining a further understanding of and familiarity with ASE-type questions.

Instructor Directions

1. Direct students to read and individually answer the “ASE-Type Questions” located in the Wrap-up section at the end of Chapter 11. Allow approximately 10 minutes for this part of the activity.

2. Facilitate a class review and dialogue of the answers, allowing students to correct responses as may be needed. Use the quiz question answers noted below to assist in building this review.

3. You may wish to ask students to complete the activity on their own and turn in their answers on a separate piece of paper.

Answers to ASE-Type Questions

1. Tech A says that the first step in performing an engine removal and installation procedure is to research the appropriate service information. Tech B says that looking up service information is a waste of time for an experienced technician. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: a

2. Tech A says that front-wheel drive, rear-wheel drive, and all-wheel drive are examples of drive train configurations. Tech B says that before an engine fails, there are usually warning signs such as dash warning lights indicating low oil pressure, high operating temperature, or abnormal engine noises. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: c

3. Tech A says that when disconnecting the battery, remove the positive terminal from the battery first. Tech B says that you should disconnect the negative terminal first when preparing to disconnect the battery. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: b

4. Tech A says that a fuel injection system automatically relieves pressure when the engine is turned off. Tech B says that you will need to relieve fuel pressure from most fuel-injected vehicles before disconnecting the lines. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: b

5. Tech A says that if refrigerant removal is necessary, air-conditioning refrigerant must be removed with an approved recycling machine. Tech B says that if refrigerant removal is needed, it is much better to release it into the atmosphere because modern refrigerants are safe. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: a

6. Tech A says that the boiling point of engine coolant is increased by the coolant properties, and the cooling system pressure is maintained by the pressure cap. Tech B says that if a technician were to remove a cooling system pressure cap from a hot engine, the sudden reduction in the coolant boiling point could boil the water violently and scald the technician. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: c

7. Tech A says that after starting the engine, it should be revved higher than 4000 rpm for a few minutes to break in the rings. Tech B says that after starting the engine, connect a diagnostic scan tool to the DLC and check for DTCs. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: b

8. Tech A says that a technician needs to make sure an engine hoist is rated for the lifting capacity needed for the engine being removed. Tech B says that when installing a manual transmission, a clutch alignment tool is needed. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: c

9. Tech A says to check all fluid levels before starting a newly installed engine, especially the engine oil and coolant levels. Tech B says that to ensure that the piston rings are seated properly and that the camshaft and other internal components are not damaged, it is important to follow appropriate engine break-in procedures. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: c

10. Tech A says that a torque converter should engage at three different levels as it is being installed in a transmission. Tech B says that the torque converter requires an alignment tool when installing it in the transmission. Who is right?

a. Tech A

b. Tech B

c. Both A and B

d. Neither A nor B

Answer: a

Assignments

A. Review all materials from this lesson and be prepared for a lesson quiz to be administered (date to be determined by instructor).

B. Direct students to read the next chapter in Fundamentals of Automotive Technology: Principles and Practice as listed on your syllabus to prepare for the next class session.

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