2013년 11월 30일 토요일

About 'replacement engines'-California - Replacement Engines - Japanese Replacement Engines - Engine Changes







About 'replacement engines'-California - Replacement Engines - Japanese Replacement Engines - Engine Changes








Timing               chains               are               interesting.

Especially,               when               you               find               you               suddenly               need               to               replace               one.

I               was               just               driving               my               way               down               the               highway               and               had               reached               my               exit.

Letting               off               the               throttle               I               let               my               old               truck               drift               to               bleed               off               my               speed               so               I               could               negotiate               the               off               ramp               with               a               good               degree               of               safety               when               the               engine,               with               no               warning               simply               quit.

I               let               her               roll               off               onto               the               shoulder               while               I               still               had               some               momentum               and               got               out               of               traffic.

The               next               few               minutes               were               spent               in               a               great               deal               of               engine               cranking               and               snooping               under               the               hood               trying               to               determine               just               what               had               happened.

Considering               the               accumulated               mileage               on               the               engine               and               the               occasional               backfire               I               was               getting               while               cranking,               the               likely               problem               seemed               to               be               that               the               timing               gear               had               slipped               a               tooth               or               two..and               the               engine               was               now               out               of               time               so               badly               only               replacement               gears               and               chain               would               bring               it               back               to               life.
               One               tow               truck               ride               and               at               the               house               I               am               under               the               hood               beginning               the               process               of               replacing               those               gears               and               chain               and               wondering               how               long               all               this               might               take.

Off               comes               the               fan               shroud.

The               serpentine               belt               and               the               fan               and               pulley               assembly.

The               water               in               the               radiator               gets               drained               away               and               then               the               water               pump               is               removed.

Next               it               was               under               the               truck               to               drain               the               engine               oil               and               loosen               all               twenty               two               bolts               and               nuts               that               hold               on               the               oil               pan.

Removing               the               pan               actually               wasn't               needed               so               I               just               took               off               all               the               nuts               that               hold               it               on               except               the               ones               at               each               corner.

I               just               needed               it               to               come               down               a               little               bit               to               gain               clearance               for               the               timing               chain               cover               to               slip               on               and               off.

And               as               long               as               I               was               under               there,               I               also               popped               off               the               harmonic               balancer               as               it               needed               to               come               off               anyway.

This               required               the               use               of               a               puller               device               which               I               rented               at               the               parts               store.
               Okay...all               is               ready               now               to               pop               off               the               chain               cover               and               get               into               the               real               guts               of               this               latest               breakdown.

The               chain               cover               is               only               held               on               by               about               six               small               bolts.

I               removed               the               bolts               and               gently               pulled               the               cover               away               from               the               block.

The               manner               in               which               this               cover               is               made               makes               it               an               integral               part               of               the               oil               pan               seal.

This               is               why               the               oil               pan               had               to               be               lowered.

That               cover               has               a               seal               on               the               bottom               of               it               that               mated               to               the               oil               pan               itself.

Together,               they               formed               an               oil               tight               seal.

This               same               cover               also               has               a               circular               seal               in               the               front               so               it               can               slip               over               the               exposed               end               of               the               crank               shaft.
               The               chain               cover               off               now               I               can               see               the               timing               gears               and               the               chain.

Sure               enough,               there               is               a               tooth               missing               on               the               large               cam               gear.

The               smaller               crankshaft               gear               looks               okay               but               the               teeth               have               become               pointed               over               time               and               are               no               longer               squared               off               on               the               ends.

The               chain               is               loose               as               well               instead               of               being               taut               as               a               bow               string               the               way               it               should.

Having               stopped               off               at               the               parts               store               on               my               way               back               with               the               tow               truck               I               had               the               parts               I               needed               to               fix               all               this               right               up.
               First               we               get               the               cam               gear               off.

A               half               inch               drive               socket               wrench               removes               the               single               large               bolt               in               a               jiffy.

Pulling               the               gear               straight               out               brings               it               and               the               chain               off               at               the               same               time.

Selecting               a               sturdy               flat               edge               screw               driver               allows               me               to               wedge               the               crank               gear               off               and               it               is               soon               in               my               hands               as               well.

So               far,               so               good.

Now               we               come               to               the               touchy               part               of               all               this.

So               let               us               talk               about               timing               gears               and               chains               and               what               they               do,               to               gain               some               understanding.
               The               crankshaft               and               your               cam               shaft               are               two               separate               parts               of               your               engine.

They               are               required               to               work               together               but               accomplish               separate               things               in               order               for               your               engine               to               run.

The               crankshaft               has               the               pistons               attached               to               it               and               when               the               piston               is               forced               down               by               an               ignition..you               get               power               and               down               the               road               you               go.

But               that               power               is               really               the               result               of               an               intake               of               air,               a               percentage               of               gasoline               mixed               with               that               air,               and               a               spark.

The               air               we               need               cannot               get               to               the               piston               unless               it               passes               through               a               valve               first.

And               here               is               where               we               need               our               cam.

It               has               one               main               job               essentially.

To               open               and               close               the               intake               and               exhaust               valves               at               exactly               the               right               time,               in               the               exact               right               sequence               to               allow               a               continuous               intake               of               air               and               expulsion               of               exhaust               gases.

Getting               the               crankshaft               and               cam               shaft               to               work               together               and               in               harmony               is               what               shade               tree               mechanics               call               timing.
               I               bring               out               the               socket               wrench               again               because               I               am               going               to               need               it               shortly               to               begin               this               process               of               timing.

I               need               to               do               two               things.

First,               I               need               to               bring               the               crankshaft               up               to               what               is               known               as               Top               Dead               Center...or               TDC.

This               means               that               the               piston               in               number               one               cylinder               needs               to               be               at               the               very               top               most               point               in               it's               movement.

Top               dead               center               !
               Determining               where               the               piston               is               at               any               given               time               is               quite               easy               however.

That               crank               gear               has               a               slot               on               the               inside               surface               of               the               hole               that               has               been               bored               into               the               center               of               it               at               the               factory.

This               hole               is               there               so               the               gear               can               slip               over               the               end               of               the               crankshaft               and               this               slot               is               called               a               key               way.

And               the               shaft               has               a               raised               ridge               that               will               fit               perfectly               in               that               slot.

This               ridge               is               called               the               key.

So               the               gear               will               only               fit               on               the               shaft               one               way,               and               one               way               only.

Also,               etched               into               the               metal               of               the               gear               is               an               alignment               dimple.

You               just               attach               the               new               gear               to               the               crank               with               the               bolt               and               tighten               it               to               specifications.

Then               you               can               rotate               the               crank               until               that               dimple               which               you               have               not               taken               your               beady               little               eyes               from..is               at               the               twelve               o'clock               position.

Your               crankshaft..and               the               number               one               piston,               are               now               at               Top               Dead               Center.

Now               I               need               to               remove               that               bolt               as               I               will               need               it               later               for               the               harmonic               balancer.
               Our               next               move               is               to               get               the               new               cam               gear               on.

It               also               has               an               alignment               dimple.

On               my               engine               it               is               required               that               the               dimple               be               at               the               six               o'clock               position.

I               pop               the               gear               on               and               tighten               down               the               bolt               and               once               it               gets               tight               enough               the               entire               cam               will               move               as               I               continue               to               pull               on               my               wrench.

Once               the               cam               gear               alignment               dimple               has               reached               the               six               o'clock               position,               I               use               a               broad               blade               screw               driver               wedged               into               the               teeth               of               the               gear               to               prevent               it               moving               and               take               the               cam               gear               bolt               back               out.

Now               I               can               pop               the               gear               off               again               and               my               cam               hasn't               moved               at               all.

Picking               up               the               timing               chain               I               drape               it               over               the               cam               gear               and               slowly,carefully               loop               the               bottom               half               of               the               dangling               chain               around               the               crankshaft               gear.

If               you               do               this               right,               you               can               move               both               chain               and               cam               gear               up               and               onto               the               crank               gear,               get               the               cam               gear               placed               ,               still               with               that               dimple               at               six               o'clock,               and               a               bolt               through               it's               center               with               minimal               trouble.

With               the               bolt               now               through               the               gear               and               into               the               camshaft..the               whole               assembly               is               beginning               to               come               together.

Tighten               the               cam               gear               to               specifications.
               Now               I               take               a               look               at               the               chain               cover.

There               are               some               concerns               here.

First,               it               has               a               gasket               or               remains               of               a               gasket,               that               have               to               be               removed               and               a               putty               knife               will               do               this               in               quick               time               for               me.

I               also               look               a               the               engine               block               where               this               cover               resides,               If               there               are               any               gasket               remains               on               there               the               putty               knife               will               remove               them               easily.

The               chain               cover               also               has               a               seal               in               the               lower               front               of               it.

It               is               wisest               to               replace               this               seal               as               it               can               be               damaged               in               removing               the               cover.

And               on               the               bottom               of               the               cover               is               another               seal.

This               is               the               part               that               mates               up               to               the               oil               pan               and               I               wanted               to               make               dead               certain               these               gaskets               and               seals               were               perfect               to               prevent               oil               leaks.

Six               bolts               later               I               have               the               chain               cover               in               place               and               I               can               go               under               the               truck               and               replace               all               those               twenty               two               bolts               and               nuts               and               snug               the               oil               pan               back               up               and               against               the               engine               block               where               it               belongs.

And               again,               as               long               as               I               am               under               there,               I               put               the               harmonic               balancer               back               in               place               and               torque               it               up               to               specifications.
               That               done               I               can               concentrate               on               putting               everything               else               back               where               it               belongs               on               the               front               of               the               engine               now.

I               replace               the               water               pump               gaskets               and               considering               this               is               the               original               pump,               I               have               a               new               replacement               for               it               as               well.

The               fan               pulley               assembly               goes               on               next               and               then               the               serpentine               belt.

All               that               is               left               is               the               fan               shroud,               refill               the               radiator               with               coolant               and               replace               the               oil               filter               and               refill               with               oil..and               the               thing               should               start               right               up.
               Before               starting               the               engine               however,               there               is               one               more               thing               I               feel               I               should               check.

I               bring               out               my               inductive               timing               light.

This               is               a               stroboscopic               flash               unit               really,               that               has               the               shape               of               a               futuristic               ray               gun.

It's               job               is               to               flash               at               the               exact               moment               that               number               one               piston               fires.

On               the               harmonic               balancer               is               a               shallow               groove               cut               into               the               metal.

And               nearby,               is               a               marked               gauge               showing               a               portion               of               the               degrees               of               a               circle.

Mine               is               marked               like               BTC               -4               -2               0               +2               +3               +4               ATC.

That               little               code               deciphered               meant               that               -4               was               4               degrees               before               top               dead               center               or               BTDC.

The               zero               meant               Top               dead               Center.

And               the               numbers               with               a               plus               sign               are               degrees               of               timing               After               Top               Dead               Center..or               ATDC.

My               engine               needs               to               be               at               TDC.

All               you               have               to               do               is               use               chalk               or               whiteout               to               mark               that               groove               in               the               harmonic               balancer               so               you               can               see               it               in               the               timing               lights               flash               and               another               mark               on               the               zero               of               the               gauge               that               is               mounted               near               enough               to               the               balancer               so               you               can               see               them               at               the               same               time.
               After               attaching               my               light               I               give               the               ignition               key               a               twist               and               the               engine               springs               to               life.

I               let               it               settle               down               while               observing               the               gauges               looking               for               oil               pressure               to               come               up               and               find               all               is               well.

Outside               again               I               pick               up               the               light               and               aim               it's               barrel               down               into               the               engine               compartment               so               it               can               illuminate               the               marks               I               have               made.

Each               time               the               number               one               piston               is               fired               I               get               a               bright               flash               of               light.

Being               a               strobe,               this               light               has               the               effect               of               freezing               the               motion               of               the               rotating               crankshaft               and               I               can               clearly               see               the               mark               I               have               made               on               the               balancer               and               the               stationary               gauge.

They               are               perfectly               aligned               and               unmoving.

My               engine               is               now               said               to               be               in               time.

I               had               little               doubt               this               would               be               the               case,               but               it               is               always               good               to               confirm               things.

Since               the               distributor               had               remained               undisturbed,               there               was               no               reason               for               it               be               out               of               time               anyway.

The               timing               was               precisely               where               it               had               been               before               that               gear               tooth               had               broken               off.

The               entire               job               took               several               hours               and               I               can               rely               on               this               fix               to               last               another               hundred               thousand               miles.
               On               average,               Timing               gears               and               chains               should               be               replaced               at               the               hundred               thousand               mile               mark.

if               your               engine               uses               a               Timing               Belt               however,               You               should               replace               the               belt               at               about               sixty               thousand               miles.

One               thing               to               note               here               about               engine's               that               use               a               belt.

There               are               two               kinds               of               engine's               in               the               timing               belt               world.

Interference               and               non               interference               engines.

The               interference               engine               is               one               that               can               cost               you               a               small               fortune               if               the               timing               belt               should               break..or               even               slip               a               tooth.

And               the               reason               is               that               the               tolerances               are               so               close               in               this               engine..that               if               it               ever               comes               out               of               time               due               to               a               fault               with               the               timing               belt,               the               rising               pistons               will               impact               directly               onto               any               valves               that               happen               to               be               down               at               that               moment.

The               valves               have               "               interfered"               .This               leads               to               broken               valves,               damaged               pistons,               broken               heads               and               multi-hundred               dollar               repair               bills.

Possibly               leading               up               to               a               replacement               engine.

At               that,               will               set               you               back               a               lot               financially.
               A               non               interference               engine               does               not               have               this               damage               potential               if               the               belt               should               slip               or               break.

So               be               on               the               safe               and               wise               side               of               timing               belts.

If               your               clock               has               over               sixty               thousand               on               it,               and               you               have               never               replaced               the               belt...you               may               want               to               get               this               done.

And               also               on               the               plus               side               for               timely               belt               replacement..it               isn't               all               that               expensive.

The               belt               might               go               30               dollars               or               so,               and               a               good               garage               can               have               the               new               belt               installed               in               under               2               hours.

Or               you               can               do               it               yourself               if               you               have               the               proper               tools               and               a               free               afternoon.

But               be               sure               and               get               a               repair               manual               for               your               exact               engine.

It               will               tell               you               about               proper               gear               position,               torque               information               and               they               often               include               handy               shortcuts               you               can               use.






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