Group 34 - GM V-6 Engine

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:* Removed parts are heavy and hard to move.
 
:* Removed parts are heavy and hard to move.
 
:* Requires 3 people working simultaneously to complete the task or tasks.
 
:* Requires 3 people working simultaneously to complete the task or tasks.
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 +
{| class="wikitable sortable" style="margin: 1em auto 1em auto" border="1"
 +
 +
|-
 +
! Part Number !! Part Name !! Quantity !!  Material !! Manufacturing Process !! Function !! Picture !!
 +
|-
 +
 +
|align="center"| 1
 +
|align="center"|Throttle Body
 +
|align="center"|1
 +
|align="center"|Cast Aluminum
 +
|align="center"|Cast
 +
|align="center"|Controls the amount of air that flows into the engine
 +
||[[Image:untitled2.jpg|center|thumb|100px]]
 +
|-
 +
 +
|align="center"| 2
 +
|align="center"|Intake Manifold Cover
 +
|align="center"|1
 +
|align="center"|Composite Plastic
 +
|align="center"|Injection Molding
 +
|align="center"|Protects the intake manifold from any foreign substances
 +
||[[Image:intake_manifold_cover.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 3
 +
|align="center"|Spark Plug Coil Pack
 +
|align="center"|1
 +
|align="center"|Iron & Aluminum
 +
|align="center"|Cast
 +
|align="center"|Determines when and which spark plugs spark
 +
||[[Image:unknown_1.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 4 
 +
|align="center"|Central Fuel Injector
 +
|align="center"|1
 +
|align="center"|Plastic Body<br>Nylon Hoses<br>Aluminum Regulator
 +
|align="center"|injection mold<br>injection mold<br>cast
 +
|align="center"|6 injectors in one body, each with valves<br>that open to allow the pre-pressurized fuel to flow<br>into the proper intake ports.<br>This type of fuel injection is called Central Point Sequential Injection
 +
||[[Image:unkown_2.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 5
 +
|align="center"|Distributor rotor
 +
|align="center"|1
 +
|align="center"|Plastic Top<br>Cast Iron Shaft
 +
|align="center"|Injection Molded Top<br>Cast Shaft
 +
|align="center"|Rotates synchronously with the camshaft,<br>and sends information to the coil pack so<br>it can fire each individual spark plug as the distributor rotates
 +
||[[Image:distributor_rotor.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 6
 +
|align="center"|Upper Radiator Hose Connector
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast & Machining
 +
|align="center"|Transfer the coolant from the radiator to the engine
 +
||[[Image:upper_radiator_hose_connector.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 7 
 +
|align="center"|Exhaust Gas Recirculation Valve<br>(EGR)
 +
|align="center"|1
 +
|align="center"|Iron & Aluminum
 +
|align="center"|Cast
 +
|align="center"|Regulates the recirculation of the engines exhaust back to the intake
 +
||[[Image:oxygen_sensor.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 8
 +
|align="center"|Intake Manifold
 +
|align="center"|1
 +
|align="center"|Cast Aluminum
 +
|align="center"|Cast
 +
|align="center"|Evenly distributes air to intake ports in the cylinder heads.<br>Contains passageways for fuel delivery to intake ports.
 +
||[[Image:intake_manifold.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 8A
 +
|align="center"|Thermostat
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Regulates temperature of coolant.<br>Opens when hot to allow coolant to flow to radiator.
 +
||[[Image:thermostat.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 9 
 +
|align="center"|Crank Shaft Pulley / Harmonic Balancer
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Takes rotational energy from the crankshaft to drive a serpentine belt to power other car accessories (Alternator, etc)<br>Also dampens torsional vibration
 +
||[[Image:crankshaft_pulley.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 10 
 +
|align="center"|Water Pump Pulley
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|With a rubber belt attached, transfers power from crankshaft to the water pump
 +
||[[Image:waterpump_pulley.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 11
 +
|align="center"|Water Pump
 +
|align="center"|1
 +
|align="center"|Iron & Brass
 +
|align="center"|Cast & Machining
 +
|align="center"|Circulates coolant throughout the engine and the rest of the cooling system
 +
||[[Image:waterpump_new.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 11A 
 +
|align="center"|Water Pump Back Plate Cover
 +
|align="center"|1
 +
|align="center"|Steel
 +
|align="center"|Stamped
 +
|align="center"|Prevents coolant from leaking out of pump
 +
||[[Image:waterpump1_backplate_cover.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 12
 +
|align="center"|Engine Mounts (Left and Right)
 +
|align="center"|1 each side
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|For mounting the engine in the vehicle's engine bay and absorb vibration
 +
||[[Image:enginemounts_left_right.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 13
 +
|align="center"|Oil Cooler Adapter
 +
|align="center"|1
 +
|align="center"|Aluminum
 +
|align="center"|Cast
 +
|align="center"|Connection for an external oil filter
 +
||[[Image:oilcooler_adapter.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 14
 +
|align="center"|Oil Pickup Tube and Filter
 +
|align="center"|1
 +
|align="center"|Aluminum
 +
|align="center"|Cast
 +
|align="center"|Filters and allows oil to flow from bottom of oil pan to oil pump
 +
||[[Image:oilpickup.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 15
 +
|align="center"|Oil Pump
 +
|align="center"|1
 +
|align="center"|Steel
 +
|align="center"|Cast
 +
|align="center"|Circulates oil throughout the engine
 +
||[[Image:oilpump.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 16
 +
|align="center"|Oil Pressure Sending Unit
 +
|align="center"|1
 +
|align="center"|Iron<br>Plastic
 +
|align="center"|Cast<br>Injection Molding
 +
|align="center"|Sends information to oil pressure gauge or low oil pressure light
 +
||[[Image:oilpressure_sending_unit.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 17
 +
|align="center"|Rocker Arms and Push Rods
 +
|align="center"|6 each side
 +
|align="center"|Composite
 +
|align="center"|Process
 +
|align="center"|Push rods transfer rotational mechanical energy from camshaft to rocker arms<br>Rocker arms push down valves to open them
 +
||[[Image:rocker_arms_swing_rods.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 18
 +
|align="center"|Cylinder Head Cover/<br>Valve Cover(left and right)
 +
|align="center"|1 each side
 +
|align="center"|Composite Plastic
 +
|align="center"|Injection Molded
 +
|align="center"|Prevents oil from exiting the engine and debris from entering.<br>Contains breathers for air from blow-by to escape. One of the breathers<br>routes to the positive crankcase ventilation valve for recirculation into the intake. One of the covers also<br>contains the oil filler neck.
 +
||
 +
|-
 +
 +
|align="center"|19 
 +
|align="center"|Engine Hanger
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Provision for removing engine from the vehicle's engine bay.
 +
||[[Image:engine_mount_bracket.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 20 
 +
|align="center"|Connecting Rod Caps
 +
|align="center"|6
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Connect the connecting rod to the crankshaft via the crankpin journals.<br> Journal bearings are inserted for smooth operation.
 +
||[[Image:connecting_rod_caps.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"|21
 +
|align="center"|Crankshaft Caps / Main Caps
 +
|align="center"|3
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Hold the crankshaft to the block via the main journals.<br> Journal bearings are inserted for smooth operation.
 +
||[[Image:crankshaft_caps.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 22 
 +
|align="center"|Rear Main Cap
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Mounting of the oil pump
 +
||[[Image:rear_main_cap.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 23 
 +
|align="center"|Drive Plate / Flywheel
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Storage of rotational energy
 +
||[[Image:Drive_plate.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 24
 +
|align="center"|Oil Pan
 +
|align="center"|1
 +
|align="center"|Aluminum
 +
|align="center"|Cast
 +
|align="center"|Storage of oil to be circulated
 +
||[[Image:oil_pan.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 25
 +
|align="center"|Piston
 +
|align="center"|6
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Transfers the force created by the combustion reaction to piston rod then to the crankshaft
 +
||[[Image:piston1.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 25A
 +
|align="center"|Connecting Rod
 +
|align="center"|6
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Connects the piston to the crankshaft, transfers forces
 +
||[[Image:connecting_rod.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 25B
 +
|align="center"|Compression Ring
 +
|align="center"|12 total, 2 per piston
 +
|align="center"|Aluminum
 +
|align="center"|Cast
 +
|align="center"|Create a pressure seal between the piston and cylinder walls so adequate compression can be produced
 +
||[[Image:compression_ring.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 25C
 +
|align="center"|Oil Ring
 +
|align="center"|6 total, 1 per piston
 +
|align="center"|Aluminum
 +
|align="center"|Cast
 +
|align="center"|Prevents oil from entering the combustion chamber
 +
||[[Image:oil_ring.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 26
 +
|align="center"|Engine Block
 +
|align="center"|1
 +
|align="center"|Cast Iron
 +
|align="center"|Cast
 +
|align="center"|Houses the pistons and other working parts
 +
||[[Image:engine_block.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 27
 +
|align="center"|Crankshaft
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Takes the linear energy created by the pistons and translates it into rotational energy
 +
||[[Image:crankshaft1.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 28
 +
|align="center"|Camshaft
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|The lobes on the camshaft press tappets which raise the pushrods against<br>the rocker arms to open the valves
 +
||
 +
|-
 +
 +
|align="center"| 29
 +
|align="center"|Balance Shaft
 +
|align="center"|1
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Has weights which cause a vibration to cancel out that caused by the 90 degree cylinder banks.
 +
||[[Image:N721428034_1662905_7831.jpg|center|thumb|50px]]
 +
|-
 +
 +
 +
|align="center"| 30
 +
|align="center"|Timing Chain
 +
|align="center"|1
 +
|align="center"|Rubber
 +
|align="center"|Injection Molding
 +
|align="center"|Connects the the crankshaft, camshaft, and balance shaft so that they all spin at the correct speeds.
 +
||
 +
|-
 +
 +
|align="center"| 31
 +
|align="center"|Timing Chain Cover
 +
|align="center"|1
 +
|align="center"|Composite Plastic
 +
|align="center"|Injection Molded
 +
|align="center"|Acts as a guard to keep debris away from the timing chain
 +
||[[Image:timing_chain_cover.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 32
 +
|align="center"|Cylinder Heads
 +
|align="center"|2
 +
|align="center"|Iron
 +
|align="center"|Cast
 +
|align="center"|Each house rocker arms and valves for delivery of fuel and air into the combustion chambers.<br>The top of each combustion chamber is provided by the cylinder head.
 +
||[[Image:cylinder_head_covers.jpg|center|thumb|50px]]
 +
|-
 +
 +
|align="center"| 33
 +
|align="center"|Headgaskets
 +
|align="center"|2
 +
|align="center"|MLS - Multiple Layer Steel or Copper
 +
|align="center"|Cast
 +
|align="center"|Create seals between the block and cylinder heads<br>so necessary compression can exist and oil and coolant can flow in their respective passageways.
 +
||
 +
|-
 +
|}

Revision as of 23:23, 29 November 2009

Contents

GROUP MEMBERS

Parth S. Kalia

Keith Billianti

Chris Moyer

Tae Joon Park

Keith K Selvasakaran Bernard

GATE 1

Management Proposal and Organizational Schematic



Upon meeting each other, our team was able to come up with a mutually agreed upon scheme of work. Firstly, tasks rather than pre-assigned roles were the priority and they were assigned to members of the team such that (almost) no one person was in charge of a single task and the workload was distributed as evenly as possible. This way, almost all the tasks could be double checked by at least one other individual in the group. This was done to prevent the occurrence of mistakes and to ensure that no relevant details were left out from our final wiki page.

The titles were assigned after the tasks themselves and might not be entirely representative of the tasks themselves:


Project Manager: Parth A Kalia

  • Keeping track of dates & deadlines: Maintaining a working timetable of dates for specific tasks as relevant to the various stages of the project.
  • Point of contact: Acting as a point of contact with Prof. Devendorf and Group 18 Team Leader Meredith Canty. (preferred emailing address: parthkalia@hotmail.com)
  • Organization of tasks and data: Assigning tasks to other members depending on available data to ensure completion of tasks by the due date.
  • Making Drafts for data to be submitted on Wiki: Writing up reports for wiki page. These will be checked by the Technical Experts for errors in specific facts and data and our Organization and Communications Manager to ensure that all the required data is present.


Technical Experts: Keith M Billanti and Chris A Moyer

  • Assembling/disassembling the product: The most important task of the technical experts is to perform the assembly and disassembly of the product and gather a keen understanding of it so as to provide relevant data and facts to the Project Manager for the draft reports.
  • CAD Modeling: Keith Billanti has volunteered for the task of making CAD models of various components in the product for the third stage of the Project.
  • Proof-reading and correcting Draft Reports: Checking for errors in facts and data on reports before passing on to Wikipedia Administrator.


Organization and Communications Manager: Tae Joon Park

  • Organization: Analyze planning process and clarifying required content for due projects, in the process, monitoring for errors in organization and planning.
  • Communication: Maintaining online Message Board for all group communications and posting reminders for upcoming gates.


Wikipedia Administrator: Keith K Selvasakaran Bernard

  • Wiki Manager: To ensure the timely upload of all the required information and media before deadlines and to ensure that all parts of the Wiki are active and working. Also to decide layout and format of Wiki to ensure simplicity.
  • Media Manager: Editing photos and videos taken during dissection for upload on Wiki page.


Dissection Plan

Given several factors, we decided that it would be most effective to start the dissection process as soon as possible and will have our first session the following Wednesday. Given the size and complexity of the product, we plan on completing the dissection in two parts over two weeks in the two lab hours on Wednesdays. This gives us two extra lab hours to complete the dissection in order to make up in case of any delays leading up to the second gate.

Given that our Technical Experts have had prior experience with car engines and a strong knowledge of tools and hardware, they were able to write up an accurate list of tools required for the disassembly. They are as follows:

  • Socket Wrench Set with Sockets, Deep Sockets and Wrench Extensions.
  • Allen Keys.
  • Pulley Puller.
  • Spring Compressor.


The Product: Initial Product Assessment

Uses: The product that was given to our group for reverse engineering was a V6 Car Engine. The intended use of this model specifically is to drive cars although other types of internal combustion engines can be used for many other applications in industry and other vehicles. The product can be used for either home or professional use and its function is to convert the chemical energy from the fuel to mechanical energy that is used to drive the car.


Method of operation: The product works by igniting fuel and pressurized gas inside a chamber which then causes the combustible substances to push against the moving parts of the engine. Specifically, the fuel injectors allow a mixture of air and gasoline to enter the cylinder. The piston inside the cylinder then compresses the mixture which is then ignited by the spark plug causing the piston to shoot back out. The pistons move the camshaft which in turn drives the car. The energies used are purely chemical (i.e. contained in the air and gasoline) and are then converted into Heat and Mechanical Energy. While the intent is only to produce Mechanical Energy, Heat is a by-product of the inherent inefficiency. As explained above the operation of the engine allows it to convert Chemical Energy to Mechanical Energy and Heat (which is discharged through the exhaust and the surroundings of the engine itself). The product itself is not currently functioning, thus making it difficult to assess any of its problems.


Components: The model is a GM V6 engine with several components. These are:

  • Camshaft
  • Crank
  • A timing chain
  • 2 Heads/ Valve covers
  • 6 Rods
  • 6 Pistons
  • 12 Lifters
  • 12 Rocker Arms
  • 12 Pushrods
  • 12 Valve Springs
  • Upper and Lower Air intakes
  • Oil Pump and Oil Pan
  • Throttle Body


Complexity: Looking at each of these individual parts, they are not in themselves complex, but on a whole, the engine can be said to be around a 5 on a scale of 10. The reason for this is that we have defined complexity as a whole on the basis of moving parts and the number of components. In order to judge complexity, we only compared it to other car engines and not to other larger engines used for other applications. For a better idea, the engine on a Lamborghini (which has 4 overhead cams, 12 cylinders and 4 valves per cylinder) would be placed at 10, whereas a carbureted 4-cylinder configuration (without multi-port fuel injection) would be placed at a 1.


Materials Analysis: The Materials used in the product are primarily Cast Iron, Cast Aluminum and Stainless Steel. Other materials include rubber for the timing chain and plastic for the covers on the Valve and Cylinder heads. Given our group’s prior knowledge on car engines, we estimate that there are no other significant materials in the engine.


End User Satisfaction: When comparing the product to other equivalents V6 motors of the mid 1990’s, the Vortec outclassed other engine models due to its high fuel efficiency and its sizeable 3.8L power. Thus, we can say that end users would be quite happy with the product as a whole. Given that it is in itself a component of a car and being used indirectly by the end user, we cannot comment on its ergonomics and its ease-of-use. The regular maintenance that the end user performs would be to change the oil every 3000 miles. This does not reflect the maintenance required on a car however, just the engine itself. Anything beyond the said oil change would require professional knowledge from a certified technician.


Alternatives to the product: When trying to find other alternatives to the product, we cannot limit the criteria to the engine alone as such information would not be useful. Factors such as cost would depend on specific cases depending on any modifications to the engine itself. Therefore, we can try and compare the alternatives from a user’s point of view i.e. by comparing the cars that incorporated the Vortec 4300 and comparing them to other models in the same power class of these cars.


Various models (Chevy Astro Van, GMC Safari, GMC Jimmy, Chevy Blazer, Oldsmobile Bravada, etc) used the Vortec 4300. All of these vehicles were in the price range of $22,000 and $25,000. The alternatives were:

  • The Ford Explorer: $22,000
  • The Toyota 4runner: $25,000
  • The Mitsubishi Montero:$26,000
  • The Jeep Cherokee:$23,000
  • And the Nissan Pathfinder:$30,000


As mentioned earlier, the Vortec 4300 outclasses these models in terms of fuel efficiency and power so it was also in comparison value for money to the end user. However, despite having a track record of very few reliability issues the Nissan Pathfinder has even less Reliability issues




GATE 2

Causes for corrective action

Overall, all of our goals were accomplished in good time. Individually, all of our members were able to contribute constructively and in a timely manner. Since the dissection required coordination with the other team (Group 34), we agreed on a Wednesday meeting time and was able to complete the dissection by the 26th. Problems arose as several members were ill but we were able to keep in contact and complete the dissection. Regrettably, we were not present for the last dissection session that took place on Monday. Due to my being ill, I was unable to reply in time to Meredith Canty’s request for assistance with the tools and the Monday. In any event, my teammates would have been unable to assist with the final session on Monday. As a result, no one on the team was able to attend the Monday session but the steps have been included in our report nonetheless.


Difficulty Key to Disassembly Process

Difficulty of the described step is expressed on a scale of 5 and can be expressed as:

  • Level 1
  • Requires small and/or simple tools (e.g. Screwdriver, Socket Wrench).
  • Requires minimal use of force.
  • Removed parts are small with few fasteners (e.g. Bolts).
  • Requires no more than one person to complete.


  • Level 2
  • Requires small and/or simple tools.
  • Requires minimal use of force.
  • Removed parts are small or delicate usually with a numbers of fasteners.
  • Requires one person but also close attention.


  • Level 3
  • May require slightly larger tools (e.g. Hammer/Mallet).
  • May require use of light force.
  • Removed parts may be complex but large and need attention to prevent damage.
  • Significant number of fasteners that require attention.
  • May require 2 individuals working side by side.


  • Level 4
  • Requires use of larger and possibly specialized tools (e.g. Valve Spring Compressors).
  • Requires considerable use of force.
  • Parts removed are numerous and/or large and heavy making them difficult to move and store.
  • Requires 2 or 3 individuals working simultaneously.


  • Level 5
  • Requires largest and specialized tools that require the use of force (e.g. Pulley Puller).
  • Requires most use of force (possibly involving more than one individual).
  • Removed parts are very large, with numerous fasteners and/or delicate parts.
  • Removed parts are heavy and hard to move.
  • Requires 3 people working simultaneously to complete the task or tasks.
Part Number Part Name Quantity Material Manufacturing Process Function Picture
1 Throttle Body 1 Cast Aluminum Cast Controls the amount of air that flows into the engine
2 Intake Manifold Cover 1 Composite Plastic Injection Molding Protects the intake manifold from any foreign substances
Intake manifold cover.jpg
3 Spark Plug Coil Pack 1 Iron & Aluminum Cast Determines when and which spark plugs spark
Unknown 1.jpg
4 Central Fuel Injector 1 Plastic Body
Nylon Hoses
Aluminum Regulator
injection mold
injection mold
cast
6 injectors in one body, each with valves
that open to allow the pre-pressurized fuel to flow
into the proper intake ports.
This type of fuel injection is called Central Point Sequential Injection
Unkown 2.jpg
5 Distributor rotor 1 Plastic Top
Cast Iron Shaft
Injection Molded Top
Cast Shaft
Rotates synchronously with the camshaft,
and sends information to the coil pack so
it can fire each individual spark plug as the distributor rotates
Distributor rotor.jpg
6 Upper Radiator Hose Connector 1 Iron Cast & Machining Transfer the coolant from the radiator to the engine
Upper radiator hose connector.jpg
7 Exhaust Gas Recirculation Valve
(EGR)
1 Iron & Aluminum Cast Regulates the recirculation of the engines exhaust back to the intake
Oxygen sensor.jpg
8 Intake Manifold 1 Cast Aluminum Cast Evenly distributes air to intake ports in the cylinder heads.
Contains passageways for fuel delivery to intake ports.
Intake manifold.jpg
8A Thermostat 1 Iron Cast Regulates temperature of coolant.
Opens when hot to allow coolant to flow to radiator.
Thermostat.jpg
9 Crank Shaft Pulley / Harmonic Balancer 1 Iron Cast Takes rotational energy from the crankshaft to drive a serpentine belt to power other car accessories (Alternator, etc)
Also dampens torsional vibration
Crankshaft pulley.jpg
10 Water Pump Pulley 1 Iron Cast With a rubber belt attached, transfers power from crankshaft to the water pump
Waterpump pulley.jpg
11 Water Pump 1 Iron & Brass Cast & Machining Circulates coolant throughout the engine and the rest of the cooling system
Waterpump new.jpg
11A Water Pump Back Plate Cover 1 Steel Stamped Prevents coolant from leaking out of pump
Waterpump1 backplate cover.jpg
12 Engine Mounts (Left and Right) 1 each side Iron Cast For mounting the engine in the vehicle's engine bay and absorb vibration
Enginemounts left right.jpg
13 Oil Cooler Adapter 1 Aluminum Cast Connection for an external oil filter
Oilcooler adapter.jpg
14 Oil Pickup Tube and Filter 1 Aluminum Cast Filters and allows oil to flow from bottom of oil pan to oil pump
Oilpickup.jpg
15 Oil Pump 1 Steel Cast Circulates oil throughout the engine
Oilpump.jpg
16 Oil Pressure Sending Unit 1 Iron
Plastic
Cast
Injection Molding
Sends information to oil pressure gauge or low oil pressure light
Oilpressure sending unit.jpg
17 Rocker Arms and Push Rods 6 each side Composite Process Push rods transfer rotational mechanical energy from camshaft to rocker arms
Rocker arms push down valves to open them
Rocker arms swing rods.jpg
18 Cylinder Head Cover/
Valve Cover(left and right)
1 each side Composite Plastic Injection Molded Prevents oil from exiting the engine and debris from entering.
Contains breathers for air from blow-by to escape. One of the breathers
routes to the positive crankcase ventilation valve for recirculation into the intake. One of the covers also
contains the oil filler neck.
19 Engine Hanger 1 Iron Cast Provision for removing engine from the vehicle's engine bay.
Engine mount bracket.jpg
20 Connecting Rod Caps 6 Iron Cast Connect the connecting rod to the crankshaft via the crankpin journals.
Journal bearings are inserted for smooth operation.
Connecting rod caps.jpg
21 Crankshaft Caps / Main Caps 3 Iron Cast Hold the crankshaft to the block via the main journals.
Journal bearings are inserted for smooth operation.
Crankshaft caps.jpg
22 Rear Main Cap 1 Iron Cast Mounting of the oil pump
Rear main cap.jpg
23 Drive Plate / Flywheel 1 Iron Cast Storage of rotational energy
Drive plate.jpg
24 Oil Pan 1 Aluminum Cast Storage of oil to be circulated
Oil pan.jpg
25 Piston 6 Iron Cast Transfers the force created by the combustion reaction to piston rod then to the crankshaft
Piston1.jpg
25A Connecting Rod 6 Iron Cast Connects the piston to the crankshaft, transfers forces
Connecting rod.jpg
25B Compression Ring 12 total, 2 per piston Aluminum Cast Create a pressure seal between the piston and cylinder walls so adequate compression can be produced
Compression ring.jpg
25C Oil Ring 6 total, 1 per piston Aluminum Cast Prevents oil from entering the combustion chamber
Oil ring.jpg
26 Engine Block 1 Cast Iron Cast Houses the pistons and other working parts
Engine block.jpg
27 Crankshaft 1 Iron Cast Takes the linear energy created by the pistons and translates it into rotational energy
Crankshaft1.jpg
28 Camshaft 1 Iron Cast The lobes on the camshaft press tappets which raise the pushrods against
the rocker arms to open the valves
29 Balance Shaft 1 Iron Cast Has weights which cause a vibration to cancel out that caused by the 90 degree cylinder banks.
N721428034 1662905 7831.jpg
30 Timing Chain 1 Rubber Injection Molding Connects the the crankshaft, camshaft, and balance shaft so that they all spin at the correct speeds.
31 Timing Chain Cover 1 Composite Plastic Injection Molded Acts as a guard to keep debris away from the timing chain
Timing chain cover.jpg
32 Cylinder Heads 2 Iron Cast Each house rocker arms and valves for delivery of fuel and air into the combustion chambers.
The top of each combustion chamber is provided by the cylinder head.
Cylinder head covers.jpg
33 Headgaskets 2 MLS - Multiple Layer Steel or Copper Cast Create seals between the block and cylinder heads
so necessary compression can exist and oil and coolant can flow in their respective passageways.
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