Personal motorcycles and cars have long been transformed from luxury into a means of daily transportation. Every day the number of transport in Russia is increasing. Many owners of personal vehicles are increasingly refusing to travel to car services, and prefer to repair their favorite iron horse with their own hands.
Do-it-yourself motor repair
The trend of refusing professional repair of cars and motorcycles, and especially engines and other power elements, is explained by experts for two reasons:
- Transport owners believe that no one can fix a car better than the motorist himself.
- Prices for spare parts and services are constantly growing, many Russians cannot afford such services.
Especially relevant is the costly and complex repair of an internal combustion engine. After reading this article in full, you can safely take on the overhaul of the motor with your own hands.
Main components and parts of the engine
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 engine of any gasoline-powered car or motorcycle consists of several main components and assemblies:
- Cylinder block.
- Bracket for mounting the generator.
- Piston ring seal.
- The driving disc of the torque converter, referred to by experts as the flywheel.
- Crankshaft.
- Pistons.
- Piston-mounted rings.
- Mounting plates.
- Inserts.
- Half rings.
- Main bearing caps.
- Holder for stuffing box.
- A cover that protects the timing chain from accidental damage and dirt.
- Piston pins.
- Cranks.
- Crank caps.
- Crank bushings.
- Drain plug for easy engine oil change.
- Aluminum or steel pan located at the bottom of the engine.
- Pump for recirculation of coolant (antifreeze or antifreeze).
- An oil receiver equipped with a coarse filter that protects engine mechanisms from metal chips.
- Bushings that are installed on the connecting rod heads.
Depending on the model and complexity of the engine device, there can be much more main parts in it.
Required tools
To successfully assembledo-it-yourself engine must be carefully prepared 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, a special tool for pressing the piston pins and a torque wrench are required in order to correctly calculate the bolt torque. Ring wrenches and socket heads are best suited for assembling the motor.
Many foreign-made ICE models have special bolts. To unscrew them, you will need special keys, which can be found in auto parts stores.
To remove large and heavy engines from the body of a car in the garage, you may need a crowbar to pry the engine from below 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 fenders and radiator of the car with a thick cloth.
To remove and install the engine, a crane is usually used, and if it is not available, 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. In this case, it is not necessary to buy such a device, you can take itfor rent.
Before assembling the engine of a motorcycle or any other vehicle, you should find out that the power unit should be removed from its seat before overhaul. After that, you need to remove all attachments, pipes, 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 engine is on the stand, the power unit must be fixed with 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, you should properly disassemble it and clean it thoroughly. 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 would be useful to photograph or videotape the process of disassembling the power unit so that you do not get confused during the assembly process and assemble all the mechanisms correctly.
Begin assembly
Many Internet users are interested in the question of how to assemble the engine of a walk-behind tractor or other gasoline-powered equipment. Before starting this type of work, it is necessary to clean all engine parts from carbon deposits, oil clots, various deposits and other contaminants. After that, you can safely proceed to the assembly.
First you need to insertbearing 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 installation, it is necessary to carefully lubricate the rubbing elements with engine oil. After successful installation of the liners, you can proceed with the installation of the crankshaft in the semicircular grooves located on the cylinder block.
Next, install the thrust half rings, after lubricating them with oil. Then you should put the half rings in their place. After that, these parts must be rotated so that they are in a position in which their end parts are flush with the end of the engine bed.
Before you learn how to assemble the engine of a moped or any other equipment equipped with an internal combustion engine, you must remember that each insert of the main bearing cap in the motor must be put exactly in the place where they stood before disassembly. Before and after installation, the parts should be doused with lubricant.
Next, you need to install the cylinder covers, but before that, you should apply oil to the threads and bolts that fix the newly installed engine elements. Before figuring out how to assemble the engine yourself, the craftsman needs to remember that the cover bolts are tightened in a certain order. Usually, 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 an internal combustion engineright, you need to remember that first of all you need to install the oil pump. To do this, you must first put a gasket on it, after lubricating it with a lubricant specially designed for it. After that, the pump is easily and securely attached to the block.
Next, you need to put the connecting rod in its place, and then mount the piston pins with circlips. After this operation, it is necessary to put oil scraper ring expansion springs on the pistons. After that, they must be crimped using a special tool (puller). As a rule, there are 3 rings on each piston. When installing them, it is required to follow a certain order: first the oil scraper ring is put on, then the compression ring, and only then the top one.
To answer the question of how to assemble an engine, it must be remembered that when installing piston compression rings, it is important to install them correctly. The bottom ring differs from the rest in thickness. He also has a groove pointing down.
Next, you need to install the crankshaft journals, cylinder mirrors, connecting rod bearings and piston mandrel. During assembly, the crankshaft must be in the BDC position.
Installation of pistons in cylinders
To correctly assemble the engine, you should learn how to properly install such an important element of the internal combustion engine as pistons. They must be inserted into special cylinders, squeezing 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 crankshaft journal. However, first you need to carefully lubricate these elements with engine oil. It is necessary to tighten the mounting bolts with a torque wrench, applying the forces indicated in the repair manual for your motor model.
Next, you need to install the oil level sensor in the engine block. To do this, you need to move the crankshaft to such a position that it does not interfere with the installation of a new part. This sensor is usually mounted on one bolt. Following this operation, the flywheel is attached.
At the final stage of assembling the motor, an oil sump is installed, which is located at the bottom of the power unit. This element is mounted on several bolts.
Installing the internal combustion 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 properly 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 all additional elements to it.
Installing attachments
All attachments to be connected to the engine are listed below:
- Generator.
- Power steering pump.
- A/C compressor.
- Ignition distributor.
- Candles.
- Wires.
- Coolant pump.
- Hoses and fittings.
- Sensors and wiring.
- Filter for engineoils.
- Fuel injection system.
- Intake and exhaust manifolds.
- Torque converter disc.
- Some parts of the pendant.
After successfully connecting all the equipment to the engine, and making sure that all bolted connections are reliable, you can fill the engine with oil, and then start it, making sure that the power unit is working.
