General Engine Service Procedures
Thread Repair
1. Use a general purpose thread repair kit. These kits are available commercially.
Caution: Wear safety glasses in order to avoid eye damage.
Important:
Refer to the kit manufacturer's instructions regarding the size of the drill and tap to use.
Avoid any buildup of chips. Back out the tap every few turns and remove the chips.
2. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
3. Drill out the damaged thread. Clean out any chips.
4. Tap the hole. Lubricate the tap with light engine oil. Clean the thread.
5. Thread the insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
Important: The insert should be flush to one turn below the surface.
6. Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert.
7. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.
Cleanliness and Care
An automobile engine is a combination of many machined,honed, polished, and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.
When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.
Replacing Engine Gaskets
Gasket Reuse and Applying Sealants
Tools Required
- J 28410 Gasket Remover
- Do not reuse any gasket unless specified.
- Gaskets that can be reused will be identified in the service procedure.
- Do not apply sealant to any gasket or sealing surface unless called out in the service information.
Separating Components
- Use a rubber mallet to separate components.
- Bump the part sideways to loosen the components.
- Bumping should be done at bends or reinforced areas to prevent distortion of parts.
Cleaning Gasket Surfaces
- Remove all gasket and sealing material from the part using the J 28410 or equivalent.
- Care must be used to avoid gouging or scraping the sealing surfaces.
- Do not use any other method or technique to remove sealant or gasket material from a part.
- Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces.
- These methods of cleaning can cause damage to the component sealing surfaces.
- Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil.
- This grit is abrasive and has been known to cause internal engine damage.
Assembling Components
- When assembling components, use only the sealant specified or equivalent in the service procedure.
- Sealing surfaces should be clean and free of debris or oil.
- Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
- Components requiring lubrication will be identified in the service procedure.
- When applying sealant to a component, apply the amount specified in the service procedure.
- Do not allow the sealant to enter into any blind threaded holes,as it may prevent the bolt from clamping properly or cause component damage when tightened.
- Tighten bolts to specifications. Do not overtighten.
Use of RTV and Anaerobic Sealer
Pipe Joint Compound
Important: Three types of sealer are commonly used in engines. These are RTV sealer, anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer and amount must be used in the proper location to prevent oil leaks. DO NOT interchange the three types of sealers. Use only the specific sealer or the equivalent as recommended in the service procedure.
- Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where two non-rigid parts (such as the oil pan and the engine block) are assembled together.
- Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
- Follow all safety recommendations and directions that are on the container.
To remove the sealant or the gasket material, refer to Replacing Engine Gaskets
- Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, a sit may prevent the bolt from clamping properly or cause component damage when the bolt is tightened.
- Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
- Tighten the bolts to specifications. Do not overtighten.
RTV Sealer
- Room Temperature Vulcanizing (RTV) sealant hardens when exposed to air. This type sealer is used where two non-rigid parts (such as the intake manifold and the engine block) are assembled together.
- Do not use Room Temperature Vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold,head gasket, or other surfaces where a gasket eliminator is specified.
- Follow all safety recommendations and directions that are on the container.
To remove the sealant or the gasket material, refer to Replacing Engine Gaskets
- Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened.
- Assemble components while RTV is still wet (within 3 minutes).Do not wait for RTV to skin over.
- Tighten bolts to specifications. Do not overtighten.
Anaerobic Sealer
- Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where two rigid parts (such as castings) are assembled together When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
- Follow all safety recommendations and directions that are on the container.
To remove the sealant or the gasket material refer to Replacing Engine Gaskets.
- Apply a continuous bead of gasket eliminator to one flange. Surfaces to be resealed must be clean and dry.
- Spread the sealer evenly with your finger to get a uniform coating on the sealing surface
- Do not allow the sealer to enter any blind threaded holes, a sit may prevent the bolt from clamping properly or cause damage when tightened.
Important:
Anaerobic sealed joints that are partially torqued and allowed to cure more than five minutes may result in incorrect shimming and sealing of the joint.
Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from seating properly or cause damage when the bolt is tightened.
- Tighten bolts to specifications. Do not overtighten.
- After properly tightening the fasteners, remove the excess sealer from the outside of the joint.
Separating Parts
Important:
Many internal engine components will develop specific wear patterns on their friction surfaces.
When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure reinstallation to their original location and position.
Separate, mark, or organize the following components:
- Piston and the piston pin
- Piston to the specific cylinder bore
- Piston rings to the piston
- Connecting rod to the crankshaft journal
- Connecting rod to the bearing cap
A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
- Crankshaft main and connecting rod bearings
- Camshaft and valve lifters
- Valve lifters, guides, pushrods, pivot supports and rocker arms
- Valve to the valve guide
- Valve spring and shim to the cylinder head location
- Engine block main bearing cap location and direction
- Oil pump drive and driven gears