ix Scopes .....................................................................................60 Exhaust Gas Analyzer ........................................................61 Vehicle Protection .............................................................61 Service Information .........................................................62 Factory Service Information ............................................62 General Service Information ...........................................62 Specialized Service Information.....................................62 Schematics ............................................................................62 Troubleshooting Charts ....................................................63 Technical Service Bulletins ..............................................63 Technical Hotlines ..............................................................64 Internet Diagnostic Assistance .......................................64 Chapter 4 Building an Engine . . . . . . . . . . . .69 What Is an Engine? ...........................................................69 Internal Combustion Engine ...........................................69 Building an Engine on Paper ...........................................70 What to Use for Fuel...........................................................70 The Basic Force of an Engine ..........................................71 Trapping the Expansion ....................................................72 A Simple Engine ..................................................................72 Name the Parts ....................................................................72 Fastening the Parts .............................................................73 Lengthen the Piston ...........................................................73 Getting Fuel into the Engine ............................................74 Removable Cylinder Head ................................................74 Fuel Intake and Exhaust Passages .................................75 Valves ......................................................................................75 Four-Stroke Cycle ..............................................................76 Vacuum Is the Clue .............................................................76 You Already Have a Vacuum Pump ................................76 Where Is Your Vacuum Pump? .......................................77 Stroke No. 1—The Intake Stroke ....................................77 Stroke No. 2—The Compression Stroke .......................77 Stroke No. 3—The Power Stroke .....................................78 Stroke No. 4—The Exhaust Stroke .................................79 Completed Cycle .................................................................79 Cycle Repeated.....................................................................79 What Opens and Closes the Valves? .....................79 Camshaft ................................................................................80 Valve Lifter ............................................................................81 Camshaft Speed ...................................................................81 Turning the Camshaft ........................................................82 Timing the Valves ................................................................82 The Flywheel .........................................................................84 Engine Will Run Smoothly ...............................................84 Basic Engine Completed ...............................................84 Chapter 5 Design, Construction, and Application of Engine Components. . . . . . . . . . . . . . . . . . .89 The Engine Block ...............................................................89 Cylinders ..................................................................................90 Cylinder Sleeves...................................................................90 Securing the Sleeve .............................................................91 Pistons .......................................................................................91 Piston Materials ..................................................................92 Piston Expansion Problems .............................................92 Piston Temperature ............................................................94 Piston Construction ...........................................................94 Piston Head Shape ..............................................................94 Piston Rings ..........................................................................95 Piston Pins ......................................................................... 101 Connecting Rods ............................................................. 102 Connecting Rod Construction ..................................... 103 Connecting Rod Bearings .............................................. 103 Crankshaft ........................................................................... 104 Main Bearings ................................................................... 105 Crankshaft Throws .......................................................... 105 Crankshaft Vibration ...................................................... 106 Balance Shafts ................................................................... 106 Drilled, Ground, and Polished...................................... 107 Timing Gear or Sprocket ................................................ 107 Flywheel ................................................................................ 107 Camshaft .............................................................................. 108 Valves ...................................................................................... 110 Valve Seats .......................................................................... 110 Valve Guides ...................................................................... 111 Valve Springs ..................................................................... 111 Valve Lifters ....................................................................... 111 Turning Reduces Valve Wear ........................................ 112 Valve Timing ...................................................................... 113 Cylinder Head.................................................................... 115 Appearance Covers .......................................................... 115 Oil Pan .................................................................................... 116 Timing Cover ..................................................................... 116 Gaskets .................................................................................. 116 Sealants ................................................................................. 117 Seals ......................................................................................... 117 Engine Mounting ............................................................ 118