Notes:

1. Engine Allocation. It is possible for two students working together to complete the engine disassembly and reassembly in one hour. Groups larger than two are not recommended. With 4 engines, a group of 24 peoples can complete the project in a three hour period. Each group receives one hour of contact with an engine (4 engines x 2 people/engine-hour x 3 hours = 24 people).



2. Additional Equipment Needed. The following equipment is needed for operation of this laboratory project.
• Laboratory Coats: One per person working on the engines.
• Automotive hand cleaner: Used for clean up after completing work.


3. Appropriate Engines. It has been found that 4-cylinder automotive engines are well-suited to this project. The engines contain all of the features of a typical automotive internal combustion engine but are small enough to be easily manageable.

An overhead cam engine, with rubber timing belt is useful in that it is easy to separate the head from the block to remove a piston.

Engines should have the following components included if possible: oil pan, oil filter, dipstick, alternator, water pump, valve cover, air cleaner and air intake, fuel injectors, spark plugs, intake and exhaust manifolds, and starter motor.

It is possible to obtain engines from junked cars at automotive recycling establishments. A cost for such an engine ranges from $50 to $300. Care should be taken to determine the condition of the engine before purchasing. Often, components are removed or the engines are badly damaged in handling. Manifolds can be cracked, blocks damaged, and mounting surfaces dented. Engines left outside for extended periods can have water and rust inside the cylinders which renders the pistons inoperative.

4. Engine Preparation. To prepare an engine for use in this laboratory it must be thoroughly cleaned, dismantled, and then reassembled. A typical junk engine is very greasy and dirty. Large grease deposits should be scrapped off. Engines can then be cleaned outdoors with a hose and automotive engine degreaser. Several applications are required.

Once clean, the engine should be mounted on an engine stand. Work without an engine stand is unsafe and is not recommended. Attaching the engine to the stand requires some type of hoisting mechanism.

The engine is then taken apart. Components can be given additional cleaning as they are removed from the engine. Most fasteners are tighten rather tightly or rusted in place. A selection of quality wrenches and sockets is essential. Assistance from an individual experienced in this work is recommended.

After the engine head is separated from the block, one piston should be taken out. From this piston, the rings are removed. Removal of the rings facilitates reassembly and subsequent removal. The other pistons should be left in place.

After disassembly for the first time and cleaning of the parts and components, the engine can be reassembled for laboratory use. To allow the engine to be disassembled and reassembled quickly, approximately 1/2 of the fasteners can be omitted. This depends on the design of the specific engine used as well as a common-sense assessment of safety considerations.

The time needed for preparation of an engine, once the necessary tools and facilities are available, is 20 to 40 hours.