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| − | == Members == | + | == Executive Summary == |
| | + | The project as a whole went smoothly with a few minor problems but nothing too hard to overcome. The hardest part of the project was coordinating with Group 34 and how duties would be split between the two groups. As planned, disassembly took three weeks to finish. Some problems that were faced during the dissection were the removal of the harmonic balancer and the flywheel. The harmonic balancer required a pulley puller, which was not readily available, and the flywheel removal involved some added disassembly of the engine stand. Reassembly went smoothly knowing how to deal with the challenges that were faced during the disassembly. The overall outcome of the project was a success. All of the Gates were completed on time and all of the Group 18 members worked well together the whole way through. |
| | + | |
| | + | == Introduction == |
| | + | === Members === |
| | <ul> | | <ul> |
| | <li>Brett Bowman | | <li>Brett Bowman |
| Line 7: |
Line 11: |
| | <li>Andrew Ring | | <li>Andrew Ring |
| | </ul> | | </ul> |
| | + | |
| | + | === Product === |
| | + | [[Image:cropped engine.gif]] |
| | + | <ul> |
| | + | <li>Manufacturer: General Motors |
| | + | <li>Model: Vortec 4300 V6 Engine |
| | + | <li>Approximate year of production: 1985 |
| | + | <li>Types of vehicles engine is used for: Chevrolet Blazer, Chevrolet Astro, GMC Safari, GMC Jimmy, etc. |
| | + | <li>Our task was to reverse engineer the engine and analyze its components, how the components were manufactured, and how they come together to work as a unit. |
| | | | |
| | == Gate 1: Request for Proposal == | | == Gate 1: Request for Proposal == |
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Line 26: |
| | | | |
| | == Gate 2: Preliminary Design Review == | | == Gate 2: Preliminary Design Review == |
| | + | View our Preliminary Design Review:<br> |
| | + | [[Group_18_-_GM_V-6_Engine_Gate2]]<br> |
| | | | |
| − | ===Causes for Corrective Action=== | + | == Gate 3: Coordination Review == |
| − | | + | View our Coordination Review:<br> |
| − | The dissection of the GM V-6 Engine went very smoothly with a few minor problems. Our project plan worked out exactly as planned. The dissection took three weeks, and everyone was able to be at the lab on Wednesdays after class to work for an hour to an hour and half. The biggest challenge faced was setting up a time with the group thirty-four, and communicating with them at first. To overcome this, Meredith Canty from our group and Parth Kalia from group thirty-four exchanged emails since both are project managers. Both groups met at five on Wednesdays to work together on the dissection of the engine.
| + | [[Group_18_-_GM_V-6_Engine_Gate3]]<br> |
| − |
| + | |
| − | | + | |
| − | While dissecting the engine the groups realized that there were tools that needed to be acquired that were not offered in the lab to finish the dissection. The two tools needed were the pulley puller and the valve compressor. To get the tools needed, group thirty-four did not really offer any communication or effort into getting them. So it was left up to our group to find the tools. Andrew went to see if the Society of Automotive Engineers had the tools, and if we could use them. However, their tools were specially designed and could not be used, so Meredith tried to see if her father’s business had the tools. Her father’s business did not have them so Brett went home and got the tools needed to finish off the dissection.
| + | |
| − | | + | |
| − | | + | |
| − | Once we had the tools, the valve compressor was used to remove the valves. Then we went to use the pulley puller and realized the bolts were not long enough. To fix the problem, Brett and Derek went to Lowes to buy longer bolts. The bolts worked and the dissection was completed on Monday October 26th. For the small problems that did occur, every member was willing to help out and resolve it as fast as possible to get the dissection done in time. The group works very well together and there are no problem areas in the group.
| + | |
| − | | + | |
| − | ===Product Dissection Plan===
| + | |
| − | The table below documents the procedure that was taken to dissect a GM V6 engine. Each step includes the part that is to be removed, which tool(s) will be used, and how difficult the step is on a scale of 1 to 5. Any additional concerns about removing the part are made in the "Notes" column.
| + | |
| − | | + | |
| − | <h4>Difficulty Scale</h4>
| + | |
| − | <table border=1 cellspacing=0 cellpadding=5>
| + | |
| − | <tr><td>1</td><td>
| + | |
| − | Quickly and easily removed by hand
| + | |
| − | </td></tr>
| + | |
| − | <tr><td>2</td><td>
| + | |
| − | Quickly and easily removed using tools
| + | |
| − | </td></tr>
| + | |
| − | <tr><td>3</td><td>
| + | |
| − | Easily removed, but time-consuming or repetitive
| + | |
| − | </td></tr>
| + | |
| − | <tr><td>4</td><td>
| + | |
| − | Required moderate force, skill, or special tools
| + | |
| − | </td></tr>
| + | |
| − | <tr><td>5</td><td>
| + | |
| − | Required excessive force and time
| + | |
| − | </td></tr>
| + | |
| − | </table>
| + | |
| − | <br> | + | |
| − | | + | |
| − | <h4>The Dissection Process</h4>
| + | |
| − | <table border=1 cellspacing=0 cellpadding=5>
| + | |
| − | <tr><th>Step</th><th>Part Removed</th><th>Difficulty</th><th>Tools Used</th><th>Quantity / Size of Bolts Removed</th><th>Notes</th></tr>
| + | |
| − | <tr>
| + | |
| − | <td>1</td>
| + | |
| − | <td>Throttle Body</td><td>2</td><td>Socket Wrench</td><td>3 / 10mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>2</td>
| + | |
| − | <td>Electric Ignition</td><td>2</td><td>Socket Wrench</td><td>2 / 10mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>3</td>
| + | |
| − | <td>Upper Intake Housing</td><td>2</td><td>Socket Wrench</td><td>6 / 12mm</td><td>Vacuum lines removed by hand</td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>4</td>
| + | |
| − | <td>Intake Manifold</td><td>2</td><td>Socket Wrench</td><td>10 / 14mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>5</td>
| + | |
| − | <td>Valve Covers (2)</td><td>2</td><td>Socket Wrench</td><td>6 / 13mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>6</td>
| + | |
| − | <td>Exhaust Manifolds (2)</td><td>2</td><td>Socket Wrench</td><td>10 / 14mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>7</td>
| + | |
| − | <td>Heads (2)</td><td>2</td><td>Socket Wrench</td><td>26 / 13mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>8</td>
| + | |
| − | <td>Push Rods (12)</td><td>1</td><td>None</td><td>N/A</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>9</td>
| + | |
| − | <td>Plastic Lifter Covers (2)</td><td>2</td><td>Socket Wrench</td><td>4 / 10mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>10</td>
| + | |
| − | <td>Lifters (12)</td><td>1</td><td>None</td><td>N/A</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>11</td>
| + | |
| − | <td>Water Pump</td><td>2</td><td>Socket Wrench</td><td>4 / 14mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>12</td>
| + | |
| − | <td>Crank Pulley</td><td>2</td><td>Socket Wrench</td><td>2 / 14mm</td><td>There were supposed to be 3 bolts, but 1 was missing. The engine stand was rotated upside down after this step.</td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>13</td>
| + | |
| − | <td>Oil Cooler</td><td>2</td><td>Socket Wrench</td><td>2 / 12mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>14</td>
| + | |
| − | <td>Oil Pan</td><td>2</td><td>Socket Wrench</td><td>12 / 12mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>15</td>
| + | |
| − | <td>Clamps connecting pistons to crankshaft (6)</td><td>3</td><td>Socket Wrench, Hammer</td><td>12 / 14mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>16</td>
| + | |
| − | <td>Harmonic Balancer</td><td>5</td><td>Pulley puller, Adjustable crescent wrench</td><td>N/A</td><td>This part was stuck and required a particular type of pulley puller, as well as excessive time and force to remove.</td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>17</td>
| + | |
| − | <td>Camshaft Cover</td><td>2</td><td>Socket Wrench</td><td>2 / 6-point flange bolts</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>18</td>
| + | |
| − | <td>Camshaft Sprocket</td><td>2</td><td>Socket Wrench</td><td>3 / 13mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>19</td>
| + | |
| − | <td>Camshaft Mount</td><td>2</td><td>Socket Wrench</td><td>2 / T-20 torque bolts</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>20</td>
| + | |
| − | <td>Camshaft</td><td>1</td><td>None</td><td>N/A</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>21</td>
| + | |
| − | <td>Sprocket and Oiler Drive Gear</td><td>2</td><td>Socket Wrench</td><td>3 / 13mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>22</td>
| + | |
| − | <td>Oiler Mount</td><td>2</td><td>Socket Wrench</td><td>2 / T-20 torque bolts</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>23</td>
| + | |
| − | <td>Oiler</td><td>1</td><td>None</td><td>N/A</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>24</td>
| + | |
| − | <td>Flywheel</td><td>4</td><td>Socket Wrench</td><td>6 / 14mm</td><td>The flywheel had to be maneuvered around the engine stand.</td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>25</td>
| + | |
| − | <td>Clamps holding crankshaft (4)</td><td>2</td><td>Socket Wrench</td><td>8 / 16mm</td><td></td></tr>
| + | |
| − | <tr>
| + | |
| − | <td>26</td>
| + | |
| − | <td>Crankshaft</td><td>1</td><td>None</td><td>N/A</td><td></td></tr>
| + | |
| − | </table>
| + | |
| − | | + | |
| − | | + | |
| − | ===Images through the Dissection Process===
| + | |
| | | | |
| − | {|
| + | == Gate 4: Critical Design Review == |
| − | | [[Image:Before dissection.JPG|thumb|upright|alt=V6 prior to dissection]]
| + | View our Critical Design Review:<br> |
| − | | [[Image:Vacuum_Lines.JPG|thumb|upright|Vaccum Lines]]
| + | [[Group_18_-_GM_V-6_Engine_Gate4]]<br> |
| − | | [[Image:Overhead_View_Intake_Manifold.JPG|thumb|upright|Intake Manifold]]
| + | |
| − | | [[Image:Intake_Manifold_Removed.JPG|thumb|upright|Intake Manifold Removed]]
| + | |
| − | | [[Image:Cylinder Heads Removed.JPG|thumb|upright|Removed Cylinder Heads]]
| + | |
| − | |}
| + | |
| − | {|
| + | |
| − | | [[Image:Cylinder Head.JPG|thumb|upright|View of Cylinder Head with Valves]]
| + | |
| − | | [[Image:Oil Pan.JPG|thumb|upright|Oil Pan]]
| + | |
| − | | [[Image:Bottom View Crankshaft.JPG|thumb|upright|Crankshaft]]
| + | |
| − | | [[Image:Piston and Connecting Rod.JPG|thumb|upright|Piston with connecting rod]]
| + | |
| − | |}
| + | |
The project as a whole went smoothly with a few minor problems but nothing too hard to overcome. The hardest part of the project was coordinating with Group 34 and how duties would be split between the two groups. As planned, disassembly took three weeks to finish. Some problems that were faced during the dissection were the removal of the harmonic balancer and the flywheel. The harmonic balancer required a pulley puller, which was not readily available, and the flywheel removal involved some added disassembly of the engine stand. Reassembly went smoothly knowing how to deal with the challenges that were faced during the disassembly. The overall outcome of the project was a success. All of the Gates were completed on time and all of the Group 18 members worked well together the whole way through.
