Personal motor vehicles and cars have long evolved from luxury into a means of daily movement. Every day the amount of transport in Russia is increasing. Many owners of personal vehicles increasingly refuse to travel to car services, and prefer to repair their favorite iron horse with their own hands.
Do-it-yourself motor repair
Experts explain the tendency of refusal to professionally repair automobiles and motorcycles, and especially engines and other power elements, for two reasons:
- Owners of transport believe that no one can repair a car better than the motorist himself.
- Prices for spare parts and services are constantly growing; many Russians canβt afford such services.
Especially relevant is the expensive and complex repair of an internal combustion engine. After reading this article, you can safely take on the overhaul of the motor with your own hands.
Main components and engine parts
Before answering the question of how to disassemble and assemble the engine yourself, you need to find out what this unit consists of. So, the motor of any car or motorcycle running on gasoline consists of several main components and assemblies:
- Cylinder block.
- Bracket for mounting the generator.
- Seal for piston rings.
- Torque converter drive disc, referred to by experts as a flywheel.
- Crankshaft.
- Pistons.
- Piston rings.
- Mounting plates.
- Inserts.
- Half rings.
- Covers for main bearings.
- Gland holder.
- Cover protecting the timing chain from accidental damage and contamination.
- Piston fingers.
- Connecting rods.
- Covers for connecting rods.
- Inserts for installation on rods.
- Drain plug for convenient engine oil change.
- An aluminum or steel tray located at the bottom of the engine.
- Pump for recirculating coolant (antifreeze or antifreeze).
- An oil receiver equipped with a coarse filter that protects the engine mechanisms from metal chips.
- Bushings that are installed on the heads of the connecting rods.
Depending on the model and complexity of the engine, the main parts in it can be much more.
Necessary tools
To successfully assemble the engine with your own hands, you need to carefully prepare for this. First of all, you need to prepare a set of keys of various sizes. You may also need a universal gas key. In addition, you need a special tool for mounting the piston pins and a torque wrench to correctly calculate the tightening torque of the bolts. The best fit for assembling the motor are socket wrenches and socket heads.
Many foreign-made ICE models have special bolts. To unscrew them you will need special keys that can be found in stores that sell auto parts.
To extract large and heavy engines from a car body in a garage, you may need a crowbar to pry the motor from the bottom and disconnect the gearbox and clutch from it. To protect the paintwork of the vehicle from possible mechanical damage during the repair of the power unit, cover the wings and the radiator of the car with a dense cloth.
To remove and install the engine, a crane is usually used, and in its absence, a rope or a dense and strong cable.
When all the necessary tools are prepared for the upcoming work, you can learn how to assemble the engine of a scooter or any other vehicle.
Disassemble the motor
It is most convenient to assemble and disassemble the engine on a stand specially designed for these works. Itβs not necessary to buy such a device, you can rent it.
Before assembling the engine of a motorcycle or any other vehicle, you should find out that the power unit must be removed from its seat before overhaul. After that, you need to remove all attachments, nozzles, connectors and hoses. To do this, disconnect the flywheel together with the clutch. Then you can safely remove the internal combustion engine from the vehicle body. When the motor is on the stand, the power unit must be fixed using special bolts that are screwed into the holes on the cylinder block. In the absence of a stand, the motor can be disassembled and assembled on the floor in the garage or on a workbench.
To answer the question of how to properly assemble the engine, it should be properly disassembled and thoroughly cleaned. Be careful when disassembling so as not to damage important structural elements. Be prepared for the fact that some fasteners and gaskets will need to be replaced with new ones. It will be useful to take a picture or video of the process of disassembling the power unit so that it does not get confused during the assembly process and assemble all the mechanisms correctly.
Build start
Many Internet users are interested in the question of how to assemble a motor-block engine or other gas-powered equipment. Before starting this type of work, it is necessary to clean all motor parts from soot, oil clots, various deposits and other contaminants. After that, you can safely proceed to the assembly.
First you need to insert the bearing shells in the bed of the cylinder block. At the same time, remember that in engines with several cylinders the middle liner is different from the others, because it does not have a groove. Before assembly, carefully lubricate the rubbing elements with engine oil. After successfully installing the liners, you can proceed with the installation of the crankshaft in the semicircular grooves located on the cylinder block.
Next, install the persistent half rings, pre-lubricating them with oil. Then you should put in place the half rings. After this, these spare parts must be turned so that they are in a position in which their end parts are flush with respect to the end of the engine bed.
Before you learn how to assemble a moped engine or any other equipment equipped with an internal combustion engine, you need to remember that each liner of the main bearing cover in the motor must be put in exactly the place where they stood before disassembly. Before and after installation, parts should be doused with lubricant.
Next, you need to install the cylinder covers, but before that, apply oil to the threads and bolts that secure the newly installed engine elements. Before figuring out how to assemble the engine yourself, the master needs to remember that the cover bolts are tightened in a certain order. Typically, the order and torque of fasteners is described in the engine repair manual.
Installation of the main elements of the internal combustion engine
To answer the question of how to assemble the internal combustion engine correctly, you must remember that first of all you need to install an oil pump. To do this, you must first put a gasket on it, previously lubricating it with a specially designed grease for it. After that, the pump is easily and securely attached to the unit.
Next, you need to put the connecting rod in its place, and then mount the piston pins with retaining rings. After this operation, it is necessary to put on the expansion pistons of the oil scraper rings. After that, they must be crimped using a special tool (puller). Typically, there are 3 rings on each piston. When installing them, a certain order is required: first the oil scraper ring is put on, then the compression ring, and only then the upper one.
To answer the question of how to assemble the engine, you must remember that when installing piston compression rings, it is important to put them correctly. The bottom ring is different from the rest in thickness. He also has a groove pointing down.
Next, it is necessary to install the connecting rod journals of the crankshaft, the cylinder mirrors, the connecting rod bearings and the piston mandrel. During assembly, the crankshaft must be in the BDC position.
Installing pistons in cylinders
To correctly assemble the engine, you should learn how to correctly install such an important element of the internal combustion engine as pistons. They must be inserted into special cylinders, compressing the piston rings, so as not to accidentally bend them. After this operation, it is necessary to fix the lower part of the connecting rod to the neck of the crankshaft. However, first it is necessary to carefully lubricate these elements with engine oil. Tighten the mounting bolts with a torque wrench, using the efforts specified in the repair manual for your motor model.
Next, you need to install the oil level sensor in the block for the engine cylinders. To do this, move the crankshaft so that it does not interfere with the installation of a new part. This sensor is usually mounted on one bolt. Following this operation, a flywheel is mounted.
At the final stage of the motor assembly, an oil sump is installed, which is located in the lower part of the power unit. This element is mounted on several bolts.
Installing the engine in its place
During the overhaul of the power unit, it is important for the master to know not only how to assemble the engine, but also how to correctly install it in its place. It is fastened with bolts to special devices called pillows. Then the motor is tightened with nuts to fix it securely. Then it remains only to connect to it all the additional elements.
Attachment Installation
All attachments that should be connected to the engine are listed below:
- Generator.
- Power steering pump.
- Air conditioning compressor.
- Distributor.
- Candles
- Wires.
- Coolant pump.
- Hoses and branch pipes.
- Sensors and wiring.
- Filter for engine oil.
- Fuel injection system.
- Intake and exhaust manifolds.
- Torque converter disc.
- Some parts of the suspension.
After successfully connecting all the equipment to the engine, and making sure all the bolted connections are reliable, you can pour oil into the engine, and then start it, making sure the power unit is operational.