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Engine Assembly
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Economics and parts availability will determine how much engine disassembly is feasible. There are three main
levels of engine disassembly.
1. Short block installation.
Short block installation consists of removing the engine, transferring the external parts to the replacement
short block, and installing the engine. External parts consist of:
• Starter
• Ignition system
• Fuel system
• Muffler
2. Top-end repair
Some internal parts may be available for service. With minimal disassembly beyond what is involved in a
short block replacement, it is possible to replace the cylinder base gasket, piston, piston rings, valve and the
cam gear.
3. Complete tear down
A complete tear down may be done to re-seal the crankcase or for failure analysis. Repair of the “hard
parts” such as the bearings, crankshaft or connecting rod is likely to exceed the cost of a short block or a com-
plete engine. Complete tear down information is included in this manual so that technicians can better under-
stand the parts they are likely to come in contact with, such as the PVC system.
NOTE: The repair/replace choice in warrantable situations must be made using the 2/3 replacement cost rule.
Outside of warranty, the decision is left to the dealer and the customer.
CHAPTER 8: ENGINE ASSEMBLY