Small Engine Disassembly

A Visual Guide

Objectives:

Learn operational theory through disassembly of a small engine. Become familiar with the internal mechanisms of an internal combustion engine. Reinforce lecture-based theoretical discussions.

Procedure Notes:

Take notes and make sketches as you disassemble the engine.

This will assist you during the reassembly process.

Your engine may not be exactly like the engine in this presentation. Four different engine types are used in the laboratory in order to expose students to variations in engine design.

Steps 1 & 2:

Drain engine oil into appropriate container. Drain gasoline from engine into appropriate container.

Step 3: Disconnect the Spark Plug Cable and Remove Spark Plug

Step 4: Remove Air Cleaner & Mounting Plate if Equipped

Step 5: Remove Blower Housing

Step 6: Remove Vane Governor, Carburetor Linkage, and Armature

Step 6: Remove Vane Governor, Carburetor Linkage, and Armature

Reminder: Sketch a picture of the linkage assembly to the left of this page for reassembly purposes. 5hp models will not have a vane governor or linkage that attaches to it.

Step 7: Remove Carburetor and Fuel Tank Bolt Points

Reminder: Do not remove carburetor from tank. Some models require step 8 before this step. On 5hp models DO NOT loosen or remove the mechanical governor bar. Remove the linkage only.

Step 8: Remove Muffler

Step 9: Remove Flywheel Screen & Starter Clutch OR- Crankshaft Nut, Bell Housing, & Flywheel Screen

Step 10: Remove Flywheel

Reminder: Keep track of the flywheel key.

Note: If the engine you are working on is equipped with a Magnetron Ignition System, disregard steps 11-13. *Sketch the points & condenser assembly to the left of this page for reassembly purposes before disassembly.

Steps 11 - 13:

11. Remove Breaker Point Cover 12. Remove Breaker Points and Condenser 13. Remove the Armature Wire if Still Attached

Step 14: Remove Cylinder Head

Reminder: Sketch or note cylinder head bolt differences & locations.

Step 14: Remove Cylinder Head

Note: Turn the crankshaft and view the four-stroke cycle.

Step 15: Remove the Crankcase Cover

Tap oil fill spouts to loosen

Step 15: Remove the Crankcase Cover & Gasket

Reminder: Use caution not to tear the gasket. Oil may still be in the crankcase.

Step 16: Remove the Camshaft

Tappets may fall out. Reminder: Sketch the position of the timing marks.

Step 17: Remove the Tappets/Lifters

(may fall out when cam was removed)

Step 18: Unbolt the Connecting Rod from the Crankshaft

Reminder: Use a 6 point socket only! Sketch the orientation of the cap.

Step 19: Remove the Piston

Note: Roll the piston and crank to TDC. Next, roll the crank to BDC leaving the piston at TDC. Using your fingers, gently push the piston out of the cylinder. Do not allow the piston to fly into the air.

Step 19: Remove the Piston

X to engine front. Nipple toward X

Reminder: Note the orientation of the piston when removed from the cylinder. Create a sketch that will be used for reassembly.

Step 20: Remove the Rings and the Connecting Rod from the Piston

Note: Use a piston ring expander. Sketch the piston ring orientation if differences exist. Sketch the orientation of the connecting rod to the piston.

Step 20: Remove the Rings and the Connecting Rod from the Piston

Note: Remove G-Clips with needle nose pliers and use a 1/4 nut driver to gently tap the wrist pin out of the bosses

Step 21: Remove the Crankshaft

Reminder: Note the differences in the ends of the crankshaft.

Step 22: Remove the Valve Cover Plate

Step 23: Remove the Valve Springs and Valves

Reminder: Note possible differences in the valve springs. Some engines may have different valve keepers. See lab instructor for removal procedures.

Disassembly Completion

Upon Completion, do the following:

Place all parts in your assigned tub Place a piece of tape on your tub that has your name on it. Cover your engine parts with paper towel Place your tub in the assigned area.