1. ENGINE DISMOUNTING
The engine is dismounted from the car by first disconnecting the various connections from the body or chassis of the car. It is a lengthy procedure and a definite sequence has to be followed. In this lesson, we shall study this procedure of dismantling the various systems of the car from the engine and the engine can then be dismounted by being lifted out from the car by using a chain pulley block. Due care must be taken while the engine is lifted out as it is quite heavy and a little carelessness may cause an accident.
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Objectives After going through this lesson you will be able to: Remove the various connections that precede dismounting the engine and transmission from the car ii. Dismount the engine with the help of chain pulley block iii. Disconnect the transmission from the engine i.
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Equipment Required i. ii.
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Chain pulley block Engine stand
Removal of Battery, Bonnet, Grille and Bumper Disconnect the negative and positive cable from the battery terminals. Remove the battery clamp which is held by two nuts. Remove the battery with insulation tray, and after that remove the battery bracket. Loosen the hinge bolts on both sides and remove the engine hood which is also called the bonnet. Keep the bonnet carefully so that its paint is not scratched or damaged. Remove the front grille, held with two screws, with the help of a Phillips type screwdriver. Keep the grille aside and out of way. Fig. 1.1: Removal of bumper.
Remove bonnet lock by removing the two bolts. Remove the ground wire connected to the body on both sides. • Before removing the bumper, disconnect the couplers of parking lights as the parking lights are fixed in the bumper. The bumper can be removed next. • •
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Removal of Head Lights, Front, Upper and Lower Members Remove the head light unit on both sides after disconnecting the holder. Remove the two bolts holding the radiator to upper member of bumper. Loosen the bolts of the bumper upper member. Remove the upper and lower members of the bumper.
Fig. 1.2: Removal of head light.
Removal of Radiator Disconnect the radiator fan thermo-switch lead wire at the coupler. Disconnect the radiator fan lead wire at the coupler. Loosen the clip and disconnect the radiator outlet hose from the outlet pipe at the lower end and drain out the cooling water. Loosen the clip and disconnect the radiator inlet hose from the thermostat cap. Remove the radiator assembly along with the electric fan and the reserve tank or coolant bottle from the body. Keep aside the radiator carefully so that its fins and fan etc. are not Fig. 1.3: Removal of radiator. damaged.
Removal of Electrical and Transmission Connections Pull off ignition coil high-tension cord from the distributor. Disconnect the lead wire from distributor terminal. Disconnect the lead wire and the positive (+) battery cord from the starter motor switch. Disconnect the negative (-) battery cord from transmission case. Disconnect the clutch cable from the Fig. 1.4: Disconnection of battery cable clutch release lever and transmission from transmission case. case, by loosening the No. 12 nut.
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Disconnect the back light switch lead wire at the coupler. Release the transmission breather hose from its clamp at the transmission case. Disconnect the speedometer cable from the transmission case. Disconnect the coupler and lead wire from the alternator terminals.
Removal of Carburetor Connections Open the No. 10 nut on air cleaner cap and a No. 10 bolt on cylinder head cover to remove the air cleaner case. Remove the breather hose at the air cleaner end. This hose connects the cylinder head cover to the air cleaner. Disconnect the choke wire from the Fig. 1.5: carburetor body. Air filter and breather hose. Disconnect the accelerator wire from the carburetor body. Disconnect the carburetor solenoid lead wire at the coupler. Disconnect the fuel return hose from the carburetor body.
Removal of Connections at Fuel Pump and Transmission Disconnect the fuel pump inlet hose from the fuel pump. Disconnect the lead wire from the water temperature gauge. Disconnect the lead wire from the oil pressure switch. Hoist the car. Fig. 1.6: Hoisting the car. Disconnect the exhaust center pipe from the exhaust manifold. Disconnect the gearshift control from the transmission case. Disconnect the extension rod from transmission case. Remove the transmission drain plug using No. 10 Allen key and drain the transmission oil in a tray. Then screw in the drain plug. Disconnect the left side drive shaft from differential side gear snap rings. Similarly, disconnect the right side drive shaft. Draw out the drive shafts, left and right, from the differential side gears. Lower the car. Remove the transmission left side mounting and mounting bracket.
Dismounting the Engine Remove the nuts securing the engine mounting on the front and rear to make the engine ready for removal.
Fig. 1.7: (a) Engine rear mounting. (b) Engine mounting block.
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Set a piece of wire across the hook on the inlet manifold and transmission case so that the engine can be lifted by using a chain pulley block. As the transmission case doesn’t have a hook, install a hook of the same type as the one on the intake manifold at the position on the transmission case.
Fig. 1.8: (a) Chain pulley block. (b) Engine stand.
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Before finally lifting the engine, recheck to ascertain that all items are disconnected and free. Lift the engine with the help of a chain pulley block. Take down the engine with transmission and place it on the engine stand. Remove the lifting hook and wires.
Removal of Transmission Loosen the bolts of the clutch housing. Open the bolts holding the starter motor and remove the starter motor. Loosen the clip of water inlet pipe and its holding bracket and remove the water inlet pipe. Loosen and remove the nut holding the clutch cover and pull back the transmission.
Fig. 1.9: Starter motor.
The engine can now be mounted on the rotary stand for dismantling.
Self-check Questions 1. The engine can be dismounted by lifting out from the car by using a __________. 2. The engine hood is also called the__________. 3. Before removing the bumper, we should disconnect the couplers of___________. 4. A piece of wire is set across the hook on the ____________ and ____________ so that the engine can be lifted by using a chain pulley block
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Assignments
1.10.1 Class Assignment 1. Discuss when removal of engine from the car would be required. 2. Review the main steps of removing the engine from the car. 1.10.2 Home Assignment 1. Visit a workshop and note the other methods by which the engine can be removed from the car (besides using a chain pulley block).
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Summing Up
We saw the dismounting procedure for an engine in this lesson and you would have realized that the procedure is very methodical. The items have to be removed one after the other in a definite sequence in order that one item does not come in the way of another. Only after all the connections between the engine and the various sub-systems have been disconnected, can we remove the engine from the car.
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Possible Answers to Self-check Questions chain pulley block bonnet parking lights inlet manifold, transmission case
References
1. Maruti 800 Service Manual
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Glossary
Bonnet
Part of a car’s body which covers the engine compartment and can be lifted to give access to the engine.
Bumper
Sheet metal bar (now made of plastic) mounted across the front or rear of a car designed to absorb initial shock in a minor collision.
Chain pulley block
Lifting equipment to lift heavy loads by a hook
Grille
Decorative grid on the front of a car. Usually bright metal, but chromium-plated plastic is used on some modern cars.
Transmission
Assembly of gears in a housing that provides different gear ratios, as well as neutral and reverse, through which engine power is transmitted to the final drive to rotate the wheels