PartOne:
TAKE YOUR STUDENTSON A FIELD TRIP TO A
PROFESSIONALAUTOMACHINE SHOP
WITHOUT LEAVINGTHE CLASSROOM
Pro Automachine: 4-CylOHC Engine
PartOne:
DISASSEMBLY
AND
DIAGNOSIS
VHS 45 min
Remove valve cover, find jumped rocker
Remove idler pulley, punchmark & remove front brackets
Remove head bolts & head, find blown gasket
Mark & remove water pump & pulley, intermediate shaft,
seal housing & brackets, crank pulley, pan, sump & pump.
Number-punch main & rod caps, remove. Bearings inspect,
find loose inserts, onehot cap. Remove pistons, find scoring,
stuck rings. Cylinder boreguage check, write down results.
Remove crank, inspect.Go-no-go micrometer check vs.
individual journals check,crank found within spec.
Pro Automachine: 4-CylOHC Engine
Part Two:
ASSEMBLY
VHS 40 min
Table & parts layout Lube mainsinserts, install crank in block
Mains caps & bolts Torque to spec., degree wheel setup for final
quarter-turn Sealer & gasket for rear main seal housing, install
Mount block on stand, Lube rod inserts & cylinders, bolt protectors
Oil piston skirts & rings, set up ring compressor, install rods &pistons
Lube & install rod caps & nuts, torque caps to spec. Install
Intermediate shaft & seal housing, front main seal in housing,
housing to block, set up dial guage for crank end-play, check
Install sump to oil pump, pump to block, verify gear engagement
& seating, bolt in, lube, ready for oil pan.
Pro Automachine: 4-CylOHC Engine
Part Three:
ASSEMBLY
CONT'D & TESTING
VHS 40 min
Oil pan, sealer on matingsurface, place gaskets, sealer on neoprene
front & rear mains seal housings, install pan, check sump clearance
Clean for head gasket & install, check head & studs, set cam pulley
Install head, lube head bolts, thread in by hand, speedwrench
Torque head bolts to spec. pattern, install pulleys for crank,
intermediate shaft & timing belt. Front brackets, assemble water pump
transfer original w.p. pulley Left side brackets, thermostat,
oil pressure manifold & sender fittings, oil filter
Pressurized oil supply hookup Testing for correct oil distribution
while turning engine by hand Rockercover, paint, injector seals.
Pro Automachine:
Part Four:
ENGINE
CRANKSHAFT
BALANCING
VHS 35 min
3D Animations: V-8 crank centerlines,main & rod journals
Journals during rotation w. & without counterweights
Rods & pistons: Reciprocatinginertia stresses
Reciprocating & rotatingweight vs counterweights
Marking & weighing pistons & pins, matching weights by drilling
Marking & setup for weighing rods, all small ends, all big ends
Grinding big ends to match in setup, grinding small ends to match total
Determining and assembling bob weights, matching bob weights
Mounting crank & bob weights on machine, machine parameters
Degree wheel, readouts, angles, bob weight positioning, clamping
Spin-ups, finding correction locations, pilot holes, amounts to remove
Drilling/adding to counterweights, repeated spin-ups, adjustments
in drilling to approachbalanced condition, final balance.
Pro Automachine:
Part Five:
ENGINE
VALVE
SERVICE
VHS 25 min
3D Animations: Single cylinderOHC engine in operation at
slow, medium & fastspeeds. valves & seats w. & w.o. inserts,
combustion chamber &guides, potential oil leaks
Gateways to the cylinders. Form follows function: the right shape
for the job. Flathead orOHV, OHC. Guides Springs: pressure vs height,
loaded & unloaded.Grinding faces. Seats: cut into castings.
Seats: replaceable inserts.Replaceable guides. Three-angle cutters for seats.
Dressing stem ends: rotationfor lubrication. Recession and valve train geometry
Lubrication: keeping thepassageways clean, heads straight and flat.
Measuring heights to deck,dye-marking fit to seat. Vacuum test.
Seals: umbrella, O-ring,clip-on. Keepers, retainers, final assembly.
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