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P.A.C.RAMASAMY RAJA POLYTECHNIC COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

DISMANTLING AND ASSEMBLING OF FOUR

STROKE DIESEL ENGINE AND IDENFICATION OF

PARTS

REMOVING DIESEL ENGINE FROM THE VEHICLE:1.PARK THE VEHICLE ON A LEVEL SURFACE.2.CHOKE ALL FOUR WHEELER WITH WOODEN BLOCK.3.UNSCREW THE BONNET MOUNTINGS AND REMOVE IT ALONG WITH THE GRILL.4.DISCONNECT THE BATTERY CONNECTION AND TAKE OUT THE BATTERY.5.DRAIN THE RADIARTOR.6. DRAIN THE ENGINE OIL.REMOVE THE AIR CLEANER.7. REMOVE THE RADIATOR HOSES8.DISCONNECT THE WIRE CONNECTION OF THE STARING MOTOR AND ALTERNATOR ,HEATERPLUG CONNECTION.9.DISCONNECT THE FUEL SUPPLY PIPES FROM FUEL TANK TO FUEL PUMPS.10.DISCONNECT THE ACCELERATOR CONNECTION.

11.REMOVE THE CLUTCH AND GEAR LINKAGES.12.DISCONNECT THE PROPELLER SHAFT AND GEARBOX END.13.FIT A SUITABLE ENGINE LIFTING BRACKET.14.REMOVE THE ENGINE MOUNTING BRACKET.

Engine OverhaulCHEVY 350

Remove Engine

Place engine securely on an engine stand

Remove Accessories

Remember to take photos- bag and label the parts and fasteners

Remove Intake and Valve train Components

Label the pushrods – this is to identify if you find a bent one later to look at the other parts for that cylinder.

Remover Cylinder Heads

Remove the head bolts in reverse sequence--- Check for damage especiallybetween cylinders

The Engine’sIdentificationNumber isFound Here

Remove Lifters

Rotate the engine – it will pop the lifters up for easy of removal

Remove Oil Pan and Inspect

This is a four-bolt main – Pay attention to the oil pickup screen, look for debris

12 3

4

Mark the main and rod capsfor reinstallation

Use number and Letter sets

Remove Gaskets and Scrape Away Crud

Wiggle out the oil dipstick tube, it will be damaged if you don’t.

Remove Balancer and Front Cover

Loosen the Main BoltsIn Reverse Sequence

Remove the Harmonic balancer with the proper tool or you will damage it.

Remove TimingGears and ChainToss Them

Remove Pistons and Main Caps

Tap the pistons out with a plastic hammer– tap the mains from front to back to loosen

Remove Crank and Camshaft

Knock out the Freeze plugs Clean out water Jacket

holes

Remove Camshaft Bearings

You need a specific tool for this– clean out all bolt holes with a tap

Clean the Internal Area

Especially the oil galleries

Inspect Cylinder heads

Check everywhere, the heads are very prone to cracks and damage.

Cracks- You Don’t Want To See This

Clean the Heads

A power brush works well and inspect head for cracks again, cover and plug the ports and valves if you don’t rebuild the heads. (why wouldn’t you?)

Inspect Valve, Springs, and Rotator

Inspect For Cracks

Check Here

Valve Grinding

This resurfaces thevalve angle

Cut & Check Valve Seat

Use Prussian Blueto check the contact between valve and seat

Valve Angles

Seat 45 degrees

15 degrees

60 degrees

Clean and Inspect Pistons

At times you can reuse pistons, replacing them will improve the rebuild

Clean and Inspect the Entire Engine

Measure, Measure, Measure

Measuring throughout the rebuild process will insure you buy the necessary items

ASSEMBLING OF ENGINE PARTS

Install and Bolt Main Caps

You will want to confirm the inside diameter is correct and round

Make sure youline up the oils holefor the bearings

Bolt and Torque Crank

Use specifications and sequence for this and anything else in engine!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Over lubeEverything

Use Assembly Grease

Install Freeze Plugs

Fit the Ring

Protect the rod

Use wood in the vise

Lube the Rod Bearings

Use assembly grease

Oil the ringsUse engine oil

Prep Pistons for Installation

Align the ring gaps---in thirds

Installing Timing Chain

Mark the aligning Points with white outAnd align them for proper gear timing

Clean and Prep the Cylinder Heads

Some people send the heads out tobe reworked, or buy replacement heads

Install Rockers and Pushrods

Use plenty of lube, this is the last area that gets oil on startup

Adjust Rockers Arms

Adjust the slack out, turn the rod in your fingers and turn adjuster until the rod stops spinningDon’t over do this.

Prepare the Front Cover

Check the timing marks again just to make sure. Use a little extra sealer in the corners.

Install Front Cover

Lube seal as youplace the cover over the crank

Use specs

Install Harmonic Balancer

Use specs

Prep For Intake Manifold

Use a good sealer here to help the intake seal. Take care to keep gasket aligned

Place the Gaskets

Use a good sealer here to help the intake seal. Take care to keep gasket aligned

Use a little extra sealer in the corners

INSTALL INTAKE AND INJECTOR

You can wait for the distributor until later, if so covet the openings in the intake!!!!

Install Oil Pump and Filter

Install the oildipstick

You needTo adjustThe screen.How?

Install Oil Pan

Use a good sealant here

Don’t turn engine Over if carb is installed

Install a fuelpump also

Install AccessoriesValve covers

Exhaust manifolds

Water pump