xxiv Modern Automotive Technology
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1107
Engine Top End Disassembly . . . . . . . . . . . . 1108
Engine Front End Disassembly . . . . . . . . . . 1108
Cylinder Head Disassembly . . . . . . . . . . . . . .1111
Engine Bottom End Disassembly. . . . . . . . . .1111
Cleaning Engine Parts . . . . . . . . . . . . . . . . . . . . . .1114
Scrape Off Old Gaskets
and Hard Deposits . . . . . . . . . . . . . . . . . . . .1114
Cleaning Threads . . . . . . . . . . . . . . . . . . . . . . .1116
Power Cleaning Tools . . . . . . . . . . . . . . . . . . .1116
Cleaning Solvents. . . . . . . . . . . . . . . . . . . . . . .1117
Air Blowgun . . . . . . . . . . . . . . . . . . . . . . . . . . .1119
Chapter 58
Short Block Rebuilding and Machining . . . . . 1123
Cylinder Block Service . . . . . . . . . . . . . . . . . . . . . 1123
Inspecting the Cylinder Block. . . . . . . . . . . . 1123
Finding Cracks in the Block . . . . . . . . . . . . . 1124
Repairing Block Cracks . . . . . . . . . . . . . . . . . 1125
Checking Main Bearing Bores. . . . . . . . . . . . 1126
Line Boring the Block. . . . . . . . . . . . . . . . . . . 1127
Measuring Cylinder Block Deck Warpage . 1128
Measuring Cylinder Diameter . . . . . . . . . . . 1128
Cylinder Wear . . . . . . . . . . . . . . . . . . . . . . . . . 1128
Cylinder Honing and Deglazing . . . . . . . . . . . . 1131
Hone Grit Selection . . . . . . . . . . . . . . . . . . . . 1131
Using a Power Hone . . . . . . . . . . . . . . . . . . . 1132
Using a Flex Hone . . . . . . . . . . . . . . . . . . . . . 1134
Block Boring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1135
Overbore Sizes . . . . . . . . . . . . . . . . . . . . . . . . 1136
Overbore Limit . . . . . . . . . . . . . . . . . . . . . . . . 1136
Oversize Pistons and Rings. . . . . . . . . . . . . . 1136
Cylinder Sleeving . . . . . . . . . . . . . . . . . . . . . . 1136
Cleaning Cylinder Walls . . . . . . . . . . . . . . . . 1137
Camshaft and Balancer Bearing Installation. . . 1139
Core Plug Installation. . . . . . . . . . . . . . . . . . . . . . 1139
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . 1140
Measuring Journal Taper, Out-of-Round,
and Cheek Width. . . . . . . . . . . . . . . . . . . . . 1140
Checking for a Cracked Crankshaft. . . . . . . 1141
Checking Crankshaft Straightness. . . . . . . . 1141
Crankshaft Turning . . . . . . . . . . . . . . . . . . . . 1142
Undersize Bearing Markings . . . . . . . . . . . . 1142
Cleaning the Crankshaft . . . . . . . . . . . . . . . . 1142
Installing the Rear Main Oil Seal . . . . . . . . . . . . 1143
Two-Piece Seal. . . . . . . . . . . . . . . . . . . . . . . . . 1143
One-Piece Seal. . . . . . . . . . . . . . . . . . . . . . . . . 1144
Main Bearing and Crankshaft Installation . . . . 1144
Installing the Main Bearings. . . . . . . . . . . . . 1144
Installing the Crankshaft. . . . . . . . . . . . . . . . 1146
Checking Main Bearing Clearance. . . . . . . . 1148
Torquing the Main Caps . . . . . . . . . . . . . . . . 1148
Torque-to-Yield . . . . . . . . . . . . . . . . . . . . . . . . 1149
Checking Crankshaft End Play. . . . . . . . . . . 1151
Replacing the Pilot Bearing. . . . . . . . . . . . . . 1151
Piston Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1151
Cleaning Piston Ring Grooves . . . . . . . . . . . 1152
Measuring Piston Wear . . . . . . . . . . . . . . . . . 1152
Measuring Piston Clearance . . . . . . . . . . . . . 1153
Measuring Piston Ring Gap . . . . . . . . . . . . . 1153
Checking Ring Groove Depth. . . . . . . . . . . . 1153
Piston Pin Service . . . . . . . . . . . . . . . . . . . . . . . . . 1153
Piston Pin Clearance . . . . . . . . . . . . . . . . . . . 1153
Free-Floating Pin Service. . . . . . . . . . . . . . . . 1154
Pressed-In Pin Service . . . . . . . . . . . . . . . . . . 1154
Measuring Piston Pin Wear
and Clearance . . . . . . . . . . . . . . . . . . . . . . . 1156
Connecting Rod Service . . . . . . . . . . . . . . . . . . . . 1157
Rod Small End Service. . . . . . . . . . . . . . . . . . 1157
Rod Big End Service. . . . . . . . . . . . . . . . . . . . 1157
Checking Rod Straightness . . . . . . . . . . . . . . 1158
Rebuilding Connecting Rods . . . . . . . . . . . . 1158
Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . 1158
Installing Oil Rings. . . . . . . . . . . . . . . . . . . . . 1158
Installing Compression Rings. . . . . . . . . . . . 1159
Piston Ring Gap Spacing. . . . . . . . . . . . . . . . 1159
Measuring Piston Ring Side Clearance . . . . 1159
Installing the Piston and Rod Assembly . . . . . . 1161
Protecting the Crankshaft . . . . . . . . . . . . . . . 1162
Installing Piston and Rod in Block. . . . . . . . 1162
Checking Rod Bearing Clearance. . . . . . . . . 1163
Torquing Connecting Rods . . . . . . . . . . . . . . 1163
Checking Rod Side Clearance. . . . . . . . . . . . 1164
Engine Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . 1164
Balancer Shaft Service. . . . . . . . . . . . . . . . . . . . . . 1166
Chapter 59
Engine Top End Rebuilding . . . . . . . . . . . . . . . 1171
Cylinder Head Problems . . . . . . . . . . . . . . . . . . . 1172
Cylinder Head Warpage . . . . . . . . . . . . . . . . 1172
Cylinder Head Milling. . . . . . . . . . . . . . . . . . 1173
Cracked Cylinder Head. . . . . . . . . . . . . . . . . 1174
Repairing Cracked Heads . . . . . . . . . . . . . . . 1174
Diesel Precombustion Chamber Service . . . . . . 1175
Precombustion Chamber Removal . . . . . . . 1175
Precombustion Chamber Installation . . . . . 1175
Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1175
Valve Guide Service . . . . . . . . . . . . . . . . . . . . . . . 1176
Measuring Valve Guide and Stem Wear . . . 1176
Repairing Valve Guide Wear. . . . . . . . . . . . . 1177
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . 1180
Valve Seat Resurfacing . . . . . . . . . . . . . . . . . . . . . 1180
Selecting Stone and Pilot . . . . . . . . . . . . . . . . 1180
Dressing Stone. . . . . . . . . . . . . . . . . . . . . . . . . 1181