ATASA 5 Engine Cleaning, Removal & Disassembly

ATASA 5 th Study Guide Chapter 10 Pages 255274 Engine Cleaning, Removal & Disassembly 27 Points

ATASA 5 th Engine Cleaning, Removal & Disassembly Be Certain to

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Is there a career for me that melds 2 or more of my favorite clusters?

1. Major engine repair or overhaul will require ____________ from the vehicle, while some relatively major engine repairs on the upper end can be made with the engine still in the vehicle.

ATASA 5 th Engine Cleaning, Removal & Disassembly

Removal Replacement Rehearsal

2. No matter what the engine ______ point will be, a first step preceding engine removal is cleaning the engine compartment with degreaser solution that emulsifies into a hot soapy solution with hot water.


Entry Exit Lift



3. Protecting yourself with gloves and the vehicle with ____________ covers and disposable floor mats will result in more successful major engine work.


Seat Roof Fender


4. Proceed by removing the ________, making electrical & fuel system ______________, dealing with accessories like PS & AC, draining the engine ____________, and disconnecting the exhaust system.


Hood, Disconnects, Coolant

5. Drive line components like FWD _______ shafts and RWD transmissions will have to be dealt with.


Half Quarter Full

6. The torque converter must remain with the ______________ as the engine is removed. Depending on arrangement, transmission can stay in the car, be removed before engine, or be removed with engine.


Engine Transmission Clutch

7. If bolting a ________ to an engine, threads must go into the block a minimum of 1 ½ times their O.D.


Sling Bling Chain


Engine Support Fixture



8. Once removed from the vehicle, the engine should be mounted on a __________ as soon as possible.


Stand Floor Bench


9. To assist with ______________ failure, cylinder heads as well as all wearmated parts should be marked, labeled & kept organized.


Diagnosing Predicting Guessing

10. When loosening valve train components, valves may bend on ___________ engines that slam the valves into the pistons if they are outoftime. That is not an issue with “freewheeling” engines.


Interference Interruption Interrogative



11. Cylinder head bolts should be loosened ___ or ___ turns working from the ______ of the head toward the center to prevent distortion. (Keep the head gaskets to compare with the new ones.)


1 or 2 3 or 4 5 or 6

Center Ends Middle

If either the camshaft or the lifters are damaged or worn, both should be Replaced since they are “wearmated”.


Removal of camshaft bearing caps on OHC engines must be done in steps sequentially to prevent distortion and breakage of the camshaft itself or the cam tower assembly.


A valve spring compressor is needed to remove the keepers from the valves. Keep all valve train parts in order for inspection and possible reuse. They too are wearmated.


Valve stems with peened or mushroomed tips must often be filed to get them out of the guide.



Valves that cannot be refaced without leaving 1/32” minimum margin must be replaced.


Timing components like sprockets, chains, belts & tensioners should be replaced during overhaul. They are often available as a service kit.


A ring ridge reamer is used to remove the cylinder ring ridge before pistons can be removed.


Use a center punch or number stamps to identify every connecting rod & cap and every main bearing cap before removal. Stamp them on the external flat surfaces.


Rod bolts should be covered with protectors to prevent crankshaft rod journal damage during removal.




Mark the flywheel/flex plate to maintain balance during reassembly .


It is wise to plastigage ® bearings at disassembly to determine wear, as well as during reassembly to determine new bearing clearance.


Remove all core plugs (freeze plugs) & oil gallery plugs prior to block cleaning.


For decisions on machining & parts ordering, measurements must be taken. ATASA 5 th Engine Cleaning, Removal & Disassembly

12. Cleaning methods depend upon the component to be cleaned and the ___________ of which it is made. Incorrect cleaning methods or agents could be more harmful than no cleaning at all!

Year Material Country


13. Contaminants fall into 4 categories: 1) ________ ___________ soils, 2) _____________ soils like petroleum byproducts combustion by products, & coatings, 3) rust, & 4) mineral deposits/scale.

WaterSoluble, Organic Soils


14. The 3 basic processes for cleaning automotive parts are: 1) __________________ cleaning, 2) ________________, and 3) ___________________ cleaning.

Chemical, Thermal, Abrasive


15. Parts washers, soak tanks, and hot spray tanks are examples of _____________ cleaning.

Chemical Thermal Abrasive


16. ______________ cleaning ovens operate between 650° – 800° F to oxidize greases & oils into ash.

Chemical Thermal Abrasive


17. Shot ____________, tumbling, vibratory cleaning, and scraping with power tools are examples of the abrasive cleaning processes.

Blasting


Note: Shot Peening is different than Shot Blasting

18. Once parts are thoroughly cleaned, crack _______________ and repair can be done. Before repairing damaged engine parts, it is advisable to determine the cause of the fatigue & failure.

Detection or

Inspection


19. Common methods of crack detection are: 1) _________________ checks on a cylinder block or head, 2) ____________ __________ ___________ (MPI) done to cast iron parts, also known as magnafluxing ® , and

3) ______ penetrant, that can be done on iron as well as aluminum.

Pressure Magnetic Particle Inspection Dye







ATASA 5 th Engine Cleaning, Removal & Disassembly Magnaflux ® method is applied for crack

detection during crankshaft testing. The crank is previously soaked with a liquid which is sensitive to magnetism and ultraviolet light.

The grinding process starts after each part has been measured very meticulously.




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ATASA 5 Engine Cleaning, Removal & Disassembly