8. ENGINE REMOUNTING We started this course with dismounting the engine from the car. This was because we wanted to overhaul two components of the power train, namely the clutch and the transmission, both of which were connected to the engine. Hence in order to gain access to the clutch and the transmission we needed to remove the engine from the car. In lessons 2 and 3 to 7 of this course we dismantled, inspected, and then re-assembled the said sub-systems. Now is the turn to re-mount the transmission onto the engine and the engine in the car. In this lesson we will place the engine along with the transmission in the car and fix the mountings of the engine and the transmission. In effect, the entire procedure for dismounting will be reversed.
8.0
Objectives
After going through this lesson you will be able to: i. Place the engine along with the transmission in the car ii. Make other connections etc and complete the remounting procedure
8.1 i.
8.2
Fig. 8.1: (a) Engine. (b) Release bearing.
Equipment Required Chain pulley block
Transmission Assembly
Fig. 8.2: Transmission.
Fig. 8.1 shows an assembled engine on the stand. The clutch shaft has external splines which fit into the internal splines of the hub of the clutch plate. The release bearing which presses on the diaphragm spring of the clutch when the clutch pedal is pressed can also be seen. •
Place the transmission onto the engine and fix the clutch housing by tightening the bolts.
To tighten nuts onto the bolts, two spanners have to be used in order to prevent the rotation of the bolt or nut.
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8.3 •
Fix the front engine mounting bracket to the transmission.
Self Starter Mount the starter motor, taking care to see that the pinion of the motor meshes with the ring gear of the flywheel.
Fig. 8.3: (a) Starter motor. (b) Slot in clutch housing.
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Secure the starter motor in place with the help of two bolts. Fix the shield onto the lower portion of the clutch housing.
The shield prevents dirt and water from reaching the clutch. There is also a slot in the clutch housing for inserting a screw driver and placing it in between the teeth of the flywheel ring gear to stop the rotation of the crankshaft while opening the crankshaft V-belt pulley.
8.4 •
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Engine Mounting Lift the engine with the help of a chain pulley block and lower the engine in the car carefully. Place the engine mountings in position and tighten the nut. Fix the transmission bracket in place. Fix the transmission mounting to the bracket. Fix the mounting to the body of the car. Remove the lifting hook from the engine.
Fig. 8.4: Chain pulley block.
Self-check Questions 1. 2. 3. 4.
Why two spanners have to be used to tighten nuts onto the bolts? Why is the shield fixed in the lower portion of the clutch housing? Why is there a slot in the housing? How many mountings are used to mount the engine and transmission in the car?
8.5 Other Components and Connections • •
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Place the carburetor on the inlet manifold. Connect the fuel pipe between the pump and the return flow pipe. Make connections of the solenoid coupler. Fig. 8.5: (a) Carburetor. (b) Solenoid coupler.
Insert the pipe in the vacuum unit of the air conditioner. Connect the accelerator and the choke wires. Make connections of the temperature gauge and the oil pressure switch. Push the axle and fix the groove in the drive axle onto the differential snap ring. Fix the odometer cable in the transmission. Fix the breather hose in the transmission. Fix the clutch cable. Fix the coupler of the reverse gear switch. Clamp the negative from the battery to the transmission.
The connection from the negative of the battery serves to provide the negative earthing. •
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Make connections to the solenoid switch, one from the ignition coil and one from the main switch and the heavy duty battery cable. Make connections of the alternator coupler and the field winding. Fix the exhaust pipe to the exhaust manifold. Pour engine oil and close the filler cap.
Fig. 8.6: Clutch cable.
Fig. 8.7: Connecting battery cable to solenoid switch.
Fig. 8.8: Alternator coupler.
Fig. 8.9: (a) Exhaust pipe. (b) Radiator hose pipe.
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Pour transmission oil and check the level with the dipstick. Fix the battery bracket with the help of five bolts. Fix the upper and the lower members of the bumper. Fix the alternator cable in the clips provided on the lower member so that it does not hang free. Fix the bonnet lock on the upper member plate. Mount the radiator with the help of two bolts. Make hose pipe connections. Make electrical connections of the thermo-switch, the electric fan, and the air conditioner. Lift the car. Fix the gear mounting rod and the gear shifter rod. Lower the vehicle. Fig. 8.10: Gear mounting rod. Fix the high tension leads of the coil and the low tension terminal of the distributor. Fix the earth wire of the parking light, the side indicator light and the body. Fix seven bolts of the bumper. Make connections of the headlights. Mount the headlights, screwing them in place. Fix the front grille. Place the battery and clamp the cables to the terminals. Place the coolant bottle and connect the pipe to the radiator overflow pipe. Fix the bonnet to the car with the help of four bolts.
8.6 Home Assignment 1. Write down as many connections as you can, that are made after placing the engine in the car, preferably in the order given in the lesson.
8.7 Summing Up We learnt in this module to mount the engine on the car, to make connections of the various systems and to adjust the free play of the cables. The oil and the
coolant are filled to specified levels and it is checked that all the parts are in place. The engine is then started and any oil leaks and abnormal noise etc are looked into.
8.8 Possible Answers to Self-check Questions 1. in order to prevent the rotation of the bolt or nut. 2. The shield prevents dirt and water from reaching the clutch. 3. The slot in the clutch housing is provided for inserting a screw driver and placing it in between the teeth of the flywheel ring gear to stop the rotation of the crankshaft while opening the crankshaft V-belt pulley. 4. 2 engine mountings and 1 transmission bracket and mounting toward the left side
8.9 References 1. Maruti 800 Service Manual
8.10 Glossary Breather hose
Breather tube - A tube that connects the left and right bellows of a rack-and-pinion steering gear.
Carburetor
Device in the fuel system that mixes petrol and air, atomizing the petrol as it does so, in varying proportions to suit engine operating conditions.
Engine mounting
Piece of moulded rubber and metal interposed between the engine and chassis frame or body of the car to prevent engine vibrations from being transmitted to the car
Exhaust manifold
Iron casting or group of pipes bolted to the engine in line with the exhaust ports. Exhaust gases pass through the manifold into the exhaust system.
High tension lead
Heavily insulated lead from the centre of the coil to the distributor cap, and also the leads from the distributor cap to the plugs. The insulation is usually plastic coated to protect the inner insulation.
Odometer cable
Cable which transmits rotations to the distance recorder
Radiator
Device for dissipating heat from the water in a car’s cooling system; consists of thin-walled passages with large surface areas through which the water circulates.
Ring gear of the flywheel
Ring gear - An outer gear in a planetary gear set or the large gear used in the differential.
Solenoid switch
Solenoid - An electromagnetic switch that uses a movable core.
V-belt pulley
Pulley which carries the V-belt to drive the fan, generator, and pump in the engine