Automotive Engine Rebuilding

Automotive Engine Rebuilding

by James G. Hughes

Hardcover(Older Edition)


Product Details

ISBN-13: 9780130537867
Publisher: Prentice Hall Professional Technical Reference
Publication date: 10/12/1989
Edition description: Older Edition
Pages: 589
Product dimensions: 8.67(w) x 11.03(h) x 1.26(d)

Table of Contents

1. Safety and Shop Practice.
2. Tools and Equipment.
3. Basic Review of Engine Operation.
4. Diagnosing the Need for Engine Teardown.
5. Engine Identification and Reference Material.
6. Remove of Engine from Vehicle.
7. Disassembling the Engine.
8. Cleaning Parts.
9. Measurement Inspection.
10. Locating Cracks and Casting Repairs.
11. Ordering Engine Parts.
12. Block Reconditioning.
13. Cylinder Head Surfacing.
14. Valve Guide and Rocker Arm Stud Service.
15. Valve and Valve Seat Service.
16. Valve Components.
17. Assembling the Cylinder Head.
18. Camshafts and Lifters.
19. Crankshafts and Flywheels.
20. Connecting Rods and Piston Pins.
21. Pistons and Rings.
22. Bearings.
23. Oil Pumps.
24. Sealing the Engine.
25. Assembly and Break-In.
Sample ASE (NIASE) Test Questions.


There have been more changes in engines in the last ten years than in the prior forty#151;and there's still more to come.

We have seen an incredible evolution of the four-stroke gasoline, internal combustion engine in the past decade. Weight is down, performance per liter is up, fuel economy is better, emissions are lower, and overall engine durability has improved in many cases. Modern engines run faster and hotter. They employ lighter materials and more critical tolerances.

However, despite all the changes, if you step back and look closely, there is a pattern. All these changes have been made for one or more of the following reasons:

  • to increase horsepower to improve fuel mileage to lower emissions
  • to reduce noise, vibration, and harshness (NVH)
  • to save weight to cut production costs

Manufacturers are looking for the highest possible output from the lightest engine with the lowest possible internal friction that meets all the emissions laws.

Most of the changes that have been made have one primary objective. This objective usually affects one or two more on the above list, either pro or con, so it becomes a balancing act for the engineer and, ultimately, the rebuilder. Keeping the six objectives in mind, this book will take a look at what has changed, and what implications there may be for the engine repair technician or rebuilder.

The Ford 4.6L SOHC "modular" engine is one such example of this change. It is called "modular" because the engine is part of a family of engines intended to have a common architecture so production tooling and interchangeable parts can be shared. Although this idea looks good on paper, it hascreated problems for the rebuilder because of the many variations. For example, the 4.6L engines built in the Windsor plant are significantly different from those built in the Romeo plant. Additionally, there are different production changes in each plant from year to year. At present, there are at least eight different short blocks and seven head combinations for this one engine!

In any case, the person doing engine repair or rebuilding today has to be able to perform accurate diagnosis, analyze failed parts, determine the reason(s) for the failure, and do the work with great attention to detail.

This book is intended to teach the concepts and procedures of engine work. The theories and practices covered have application to present-day as well as older engines. It can be used for rebuilding older engines, high-performance engines, and current production engines. This includes both import and domestic engine types. "State-of-the-art" engine machining techniques and procedures have been included.

This edition incorporates many new illustrations and photographs not published in any other book. The author worked closely with a major production engine rebuilder (PERA) in putting together this new edition.

This book contains the most accurate technical engine rebuilding information available to date in a textbook. It has been designed as a classroom-teaching instrument as well as an in-depth reference publication. Some of the photographs have actually been used successfully in court to show examples of failed parts caused by owner abuse.

The structure of this book gives the instructor flexibility in shop and classroom application. The chapters are presented following the typical sequence in which an engine would be rebuilt. However, the book's structure allows material to be selected and covered in an order best suited to the individual situation.

Some additional features incorporated into this book are as follows:

  • An Engine Teardown and Assembly Checklist Guide showing the sequence of steps to rebuild an engine. Included are spaces for recording key measurements.
  • Concepts that will help prepare individuals for the ASE Engine Repair and Engine Machinist tests are covered. There are also self-test questions and ASE-style questions at the end of each chapter to help them prepare for these tests.
  • The NATEF task lists for engine repair and engine machinist work activity.
  • Selected True Case History examples that can be applied to specific engines as well as to many other new and older engines.
  • Addresses of core suppliers, equipment manufacturers, and other suppliers.

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