ENGINE ASSEMBLY PROCESS

1. THEME:

Equipped

2. OBJECTIVES:

2.1. Technically carry out the assembly of the internal combustion engine.

2.2. Establish norms, criteria, and general procedures for assembling the engine of
combustion

2.3. Understand the importance of each step in the engine assembly process.

2.4. Improve skills in using different tools in the assembly process.

motor.

3. THEORETICAL FRAMEWORK

In the automotive park, we will find a great variety of engines, each with its own characteristics.
specific ones, therefore there will be a specific assembly process for each case, said
the process is specified by the manufacturer. The assembly process is described below
In general, what can be applied when assembling an engine, but always conducting an analysis of
the unique characteristics of each engine.

First of all, it is important to emphasize that whenever you proceed to an aesthetic job, it should be done
to maintain

The order
Cleaning, both of the workplace environment (especially avoiding dust), as well as
cleaning of the engine components that are going to be reused (avoid dust, metal shavings)
residuals from the rectification process, carbon residues, oxides, etc.
Safety, as we assemble the engine, it gains weight and it is
the importance of its adherence.
The correct use of tools.
Having a data sheet where we will find the torque values for tightening
the different components of the engine.

3.1. Assembly of the engine block.

Firstly, the engine block must be completely clean and free of obstructions.
their cooling and lubrication ducts.
We placed the engine block on our workbench in a horizontal position (fig. 1), it is
to be supported on the contact surface with the head.
We install the main bearings, it is important to analyze the position of the
bearings (fig.2) since in the same engine we can have:
bearings with a contact surface narrower or wider than the rest of the bearings.

bearings with channels for the circulation of lubricating oil.

Axial and bearing bushings in a single body.

Bearings with fixation notches in different positions.

We assembled the crankshaft and performed the clearance check for lubrication.
using the plastigage (fig.3). NOTE: the crankshaft bearings must be tightened
with the specified torque and in sequence (fig.4).

We check that there are no residues of plastigage, we apply lubricant to the bearings.
Using the bench and applying the corresponding torque, we mount the crankshaft. When we have
independent axial bearings (half-moons) from the bed bearings, we must have
beware of the mounting position (fig.5), observe that the soft material surface
go against the crankshaft and the steel face against the walls of the engine block.
We place the flywheel, subject
provisionally (we can use only two bolts).
We placed the engine in a vertical position, that is, resting on the flywheel, since
In this position, we will be assisted in assembling the pistons.
To assemble a connecting rod-piston set inside the cylinder, we must place its respective
connecting rod on the crankshaft in TDC position. It is recommended to place protectors on the
connecting rod bolts (fig. 6) to ensure that the mounting moment prevents damage to the supports of the
crankshaft.

We must test the clearance for lubrication with the plastigage in all the supports.
of the connecting rod (fig. 7). We assemble the connecting rod-piston assembly in the cylinder, but without placing the rings.

apply a thin layer of lubricant on the skirts of the piston to avoid scratching the cylinder and
noticing that the reference mark on the piston face is towards the front of the engine.
NOTE: when we install the caps or connecting rod hats (fig. 8) we must observe the
position, they should be mounted in such a way that the notches of the bearings are left
same side.
We disassembled the connecting rod-piston assembly that we tested and cleaned all remnants of plastigage.
both of the bearings and of the crankshaft surface.
We repeat the testing process on all the pistons.
Now we proceed to mount the rims on the pistons, for which we must rely on the
suitable pliers (fig. 9.) to avoid damage to the rims and their possible breakage. NOTE: the rims
they come with reference marks (such as a dot, the word TOP, the measurement, etc.), the
Rin must be mounted with the markings facing the piston head. Also, be careful not to
to confuse a fire ring with a compression one.

We lubricate:

the rings and the grooves of the piston.

- las paredes del pistón. - los cojinetes de biela.

the walls of the cylinder.

We placed the connecting rod-piston assembly in the cylinder.

We position the rim opening, as indicated by the manufacturer. But if we do not have
From the manual, we can take as a general rule (fig. 10):
We compressed the rims with the help of a metal strap and pushed the piston inside the
cylinder (fig. 11), being careful not to turn the rims to avoid changing the positioning of the
openings.

Once all the pistons are installed, we place the engine block back in position.
horizontal, we dismantled the flywheel and checked the tightening of the connecting rod bearings
and bench (fig. 12).

We set up elements such as:

Oil pump (in case it is located at the front of the crankshaft)

Rear cover with its respective seal.
Oil strainer
For engines with gear and chain distribution control, it is generally necessary to
mount the crankshaft pinion, chain guides, chain, chain tensioner and cover of the
distribution. NOTE: the tensor must be mounted in a tension-free position.

We assemble the camshaft (for engines with a camshaft in the block).

We mounted the engine block (fig. 13). Many of the gaskets for the block are made of
soft material like cork and care must be taken not to squeeze too hard to avoid
damage the packaging, also the bolts must be tightened in order (fig. 14), in such a way
that it settles down as well as possible.

We mounted the flywheel, applying the corresponding torque and in the order as
indicates it (fig. 15), to guarantee its centering. In many cases it is recommended
put LOCTITE on the bolts.
3.2. Assembly of header

We make sure that the head is completely clean and that there is no
obstructions in the cooling and lubrication ducts.
When the head is sent for a grinding process, it is generally returned to us.
with the valves seated, if not, this process must be carried out before
assemble the elements of the same. The process of seating valves is nothing more than placing a
grinding paste on the valve seat, place it on the cylinder head and with the help of a
turn the suction cup with back-and-forth movements (fig. 16). NOTE: care must be taken that
during the settling process, the valve stem should be lubricated and never
make contact with the grinding paste, as it would suffer damage along with the valve guide. And
Once the process is finished, all residue of grinding paste must be cleaned from the head.
valves.

We install the valve seals, these go into the guide with a slight pressure so...
we need a mounting tool and to give gentle taps (fig. 17).
We set up the valves (applying
a layer of lubricant in the
stem) in the same position in the
that were subjected to the settlement process.
We set up the valve springs for which we must use the appropriate tool.
(fig. 18) to avoid damage to the elements. NOTE: We must pay attention to the position of the
docks, since there are variable step docks (fig. 19), in this case the smaller step must
be against the surface of the cylinder head.

We give a few knocks on the springs so that the clips are completely secured.
centered.
We lubricate the rocker shafts and rockers, then we proceed to assemble them.
position in which they were disassembled. We must verify that the surface of the rocker
It supports against the absence of irregular wear on the valve; if this is the case, it must be corrected.
using a sharpening stone (fig.20).
We mounted the rocker arm assembly on the cylinder head.
We mounted the cylinder head on the engine block, making sure that the gasket is in place.
correctly placed.
We apply the torque specified by the manufacturer, and we tighten in the sequence.
as indicated in (fig. 21).

We assembled the intake and exhaust manifolds.

3.3. Assembly of the distribution.

For engines with timing belt control, we proceed:

Assemble elements such as: crankshaft sprocket, camshaft sprocket, tension roller,
guide roller, tensioner, drive element sprockets.
We place the tensor element in a tension-free position.
Synchronize the elements of the distribution, that is, match the marks of
synchronization of all the elements it has. An example is shown in fig. 22.
Fig. 22 – Synchronization of the
distribution

We assembled the timing belt.

Tighten the distribution belt. It should exhibit a deformation of 10 to 15mm with a
10Kg load.
Give the engine some turns to check the timing of the distribution.
Install the distribution covers
Install the motor pulley.
For engines with distribution control by gears and chain, we proceed:
We remember that generally for this type of engines, the distribution elements
they were assembled at the moment of assembling the engine block.
We synchronize the position of the camshaft with the position of the crankshaft. The crankshaft must
to be in the position of Zero degrees, that is, the first piston at T.D.C. and the camshaft in
valve crossover position (overlap) of the first cylinder.
We place the camshaft sprocket onto the timing chain.
We mounted the camshaft gear.
We tensioned the timing chain. (releasing the tensioner)
We give the engine some turns to check the correct timing of the distribution.

4. ASSEMBLY OF THE DISTRIBUTION.

We assembled all the external elements of the engine that are necessary for its
functioning, such as:

- the clutch mechanism, in which the disc must be properly centered (to use
tool to center fig.23) to avoid problems when assembling the box
changes. We must also apply the appropriate torque and follow a tightening sequence.
as indicated in fig. 24.

- The fuel pipes, taking care not to mix up the position between feed and
return. or the fuel pump.
- The alternator.
- The fan.
- Engine belts.
- The spark plug wires.
- The engine mounts, oil filter and the various supports it may have.

We assemble the ignition distributor, for which we take into account:

- Place the engine with the first piston at T.D.C. and in the final phase of compression (zero
degrees in the motor pulley
- Mount the distributor so that the rotor points to the cap of the distributor at the
tower corresponding to the first cylinder.

5. BIBLIOGRAPHY.

hthttp://www.mecanicavirtual.org/sensores.htm
Gerschler (GTZ), Automotive Technology.
Automobile electronics. 'The ABS'. Jordi Muñoz Serrano. Research paper.
www.meritorauto.com.