Group 9 - GM Inline Four Cylinder Engine - Preliminary Design Review
Gate 2: Preliminary Design Review
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The product that group 9 has to dissect is a 2.2 Liter GM inline 4 cylinder engine. Group 9 collaborated with group 24 who have the same engine to work on. Group 9 decided to take apart the belt drives, crankshaft, and camshaft. Group 24 took apart the headers and pistons. Group 9 used photographic documentation throughout the disassembly/reassembly processes. In addition to the documentation, clear labeling of all the components was used to ensure a smooth reassembly process. Dissection time was about 3 hours spread over 2 days.
Causes for Corrective Action
The dissection of the product went mostly according to plan with only a few deviations. The collaboration with group 24 went smoothly; they began by dissecting their part of the engine first, after which group 9 picked up from where they had left off. Everyone within group 9 contributed their part and worked well together, Bryan the dissection leader led the team through this gate. Everyone worked on the product and met on time as outlined in the proposal. Group 9 found that it was a very intricate process and that it would be essential to photograph and document all steps. Sometimes the group would reach a point at which they were not certain on how to proceed but after much discussion and analyzing, group 9 was able to move ahead and continue successfully.
The main challenge and perhaps the only noteworthy one (the rest were too minor to go into detail with) was removing the camshaft. It seemed as if it would not fit through the openings it was resting in. Bryan did some further research on the subject of camshaft removal and learned that it was necessary to remove the oil pump drive prior to the camshaft. After the removal of the oil pump drive the camshaft was removed with ease. This could have been prevented by previous knowledge of the engine, and how to take apart a camshaft. This delay in completion therefore caused the difficulty level to be increased. This allowed us to stay on track with the group's Gantt chart. When the Gantt chart was created, much thought and research was applied to create an accurate and true
Product Dissection Assessment
The dissection of the product did not require any special tools; various sized sockets, needle nose pliers, and a Torx T-30 were necessary to disassemble the engine. Engine fasteners and bolts were used to suspend the engine which allowed for the dissection of the engine from every angle. Bolts and torx screws were used as fasteners in the engine. Multiple people were needed to remove the crankshaft because it is the heaviest component in the engine.
For each step we list a difficulty from 1 to 5. One being easiest, task accomplished on first try with little effort. Five being the most difficult with many attempts required to perform the task correctly. The belt drives, crankshaft and camshaft were easy to take apart because it was mostly bolts holding it together. This engine is intended to be a structured disassembly. Taking it apart is not easy, but it is straightforward therefore someone with a slight understanding of engines should be able to follow a process and successfully dismantle the engine.
Group 9 began the dissection of the engine where Group 24 left off. Group 24 dissected the top of the engine including the piston/cylinder system and the header. Group 9 worked on the remaining parts consisting of the crankshaft and camshaft system which is where the dissection begins. The following steps were used to dissect the engine. Follow the steps outlined below to disassemble the engine. Please refer to the images below for clarity.
1. Removed the (3) water pump pulley bolts with a 13 mm socket 
2. Removed the water pump pulley by hand 
3. Removed the serpentine belt tensioner bolt with a 16 mm socket 
4. Removed the serpentine belt tensioner by hand 
5. Removed (3) idler pulley minor bolts with a 16 mm socket 
6. Removed (1) idler pulley major bolt and washer with 19 mm socket 
7. Removed idler pulley by hand 
8. Removed (3) water pump bolts with a 14 mm socket 
9. Removed the water pump by hand 
10. Removed (2) bolts from camshaft gasket with Torx T-30 
11. Removed (6) bolts from the timing chain cover with a 8 mm socket 
12. Removed crankshaft and timing chain cover together by hand 
13. Removed (3) camshaft plate bolts with a 10 mm socket 
14. Removed the camshaft plate by hand 
15. Removed (1) oil pump drive bolt with a 10 mm socket 
16. Removed the oil pump drive by hand 
17. Removed camshaft by hand see corrective action for high difficulty 
|Original condition all components intact||Idler pulley and serpentine belt fastener||Crankshaft in the Engine Block|
|Timing chain cover||Engine block at an angle||Engine block front view|