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Chapter16Assembly - Engine assembly Before final cleaning...

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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
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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
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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
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Engine assembly Final cleaning Coat cylinders & decks with clean oil to prevent rust Coat valves, seats, & decks with clean oil
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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
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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
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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
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Engine assembly Chemical sealers Sometimes used in place of gaskets Silicone sealers (RTV) are flexible & temp resistant Anaerobic sealers – Absence of air
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Engine assembly Head gaskets Metal-asbestos replaced with ceramic laminate Composite core copper Good compressibility, low compression, 60AA Composite core steel
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