2. 5
Engine Blocks

3. Learning Objectives
Explain how to gain access to the components in a stationary engine.
Explain how to remove a mobile engine from its installation.
Describe how to remove the basic parts from a mobile diesel engine block.
Name two popular methods used to clean engine blocks.

4. Learning Objectives Conduct a cylinder block inspection.
Inspect a cylinder and liner.
Name the two types of cylinder liners.
Describe how to install a cylinder liner.

5. Introduction This chapter describes: Cylinder blocks
Accessing diesel engine components
Cleaning engine blocks
Inspecting cylinder blocks
Installing cylinder liners

6. Cylinder Blocks Stationary diesel engines Mobile engines
Welded construction
Mobile engines
One-piece construction
Galleries
(Great Lakes Energy Systems, Inc.)

7. Accessing Components in a Stationary Engine
Serviced on location
Crankcase
Cylinder assembly
Access covers over access openings
Explosion doors
Consult manufacturer’s service manual for disassembly

8. Accessing Components in a Mobile Engine
Removed and disassembled for service
Procedure varies
Check service manual
(Mack Trucks, Inc.)

9. Removing an Engine Safely
Do not allow refrigerant to escape from hoses
Never lift engine by rocker arm shafts or strap under oil pan
Do not stand under engine while lifting
If engine drops, allow it to fall

10. Engine Disassembly Remove accessory components
Remove rocker arm covers
(Cummins Engine Co., Inc.)

11. Removing the Injectors
(Goodheart-Willcox Publisher)

12. Removing the Cylinder Head
(Cummins Engine Co., Inc.)

13. Removing the Cam Follower Housing
(Cummins Engine Co., Inc.)

14. Removing the Flywheel
(Cummins Engine Co., Inc.)

15. Removing the Oil Pan
(Cummins Engine Co., Inc.)

16. Removing the Rear Main Seal Plate
(Cummins Engine Co., Inc.)

17. Removing the Camshaft Cover
(Cummins Engine Co., Inc.)

18. Cleaning the Cylinder Liners
(Cummins Engine Co., Inc.)

19. Piston Assembly Removal
(Cummins Engine Co., Inc.)

20. Piston Assembly Removal (cont.)
(Cummins Engine Co., Inc.)

21. Crankshaft Removal Use hoist Place in V-block
(Cummins Engine Co., Inc.)

22. Engine Block Cleaning Remove oil gallery plugs and freeze plugs
Cleaning methods
Chemical
Thermal
(Cummins Engine Co., Inc.)

23. Chemical Cleaning Hot alkaline tank cleaning
Cast iron blocks
Not used on aluminum parts
Emulsion-type cleaning solution
Aluminum parts
Open steam cleaning
No longer used

24. Thermal Cleaning Ovens
Reduces oil and grease on parts
Ash removed by airless shot blasting
(Am/Pro Machinery, Inc.)

25. Cylinder Block Inspection
Perform visual inspection
Replace parts as necessary
Coat parts with joint sealing compound before reinstallation
(Cummins Engine Co., Inc.)

26. Block Deck Warpage and Height
Check warpage
Straightedge and feeler gauge
Measure deck height
Front and rear
Spray with engine oil or rust-preventive solution
(Mack Trucks, Inc.)

27. Cylinder Bores and Liners
Integral cylinder bore
Cylinder liner
Air inlet ports
Sealing rings
Liner materials
Close-grained cast iron
Porous chromium
(Detroit Diesel Corporation)

28. Inspecting Cylinder Bores and Liners
Visual inspection
Wear
Point welding
Piston slap
(Goodheart-Willcox Publisher)

29. Checking for Cylinder Taper
(Goodheart-Willcox Publisher)

30. Removing Ridges Check for ridges Remove using ridge reamer
Blend cut for smooth surface
(Cummins Engine Co., Inc.)

31. Checking the Counterbore
(Goodheart-Willcox Publisher)

32. Types of Cylinder Liners
Dry liner
Not exposed to engine coolant
Fits against water jacket wall
Wet liner
Comes in contact with engine coolant
Water-jacketed liner

33. Dry Liners
(Goodheart-Willcox Publisher)

34. Wet Liners
(Goodheart-Willcox Publisher)

35. Types of Wet Liners Lower press fit liners Reduce
Liner cavitation
Flange fretting
Integral cylinder liners

36. Removing Cylinder Liners
Use cylinder liner puller
Use inhibited acid compounds if puller cannot free liner
(Mack Trucks, Inc.)

37. Cylinder Boring Done only by machinists
Process is same for integral bores and cylinder liners

38. Cylinder Honing Eliminates peaks and valleys in wall surface
Progressive process
Coarse honing
Plateau honing
(Goodheart-Willcox Publisher)

39. Deglazing Cylinder Walls
Removes scuffs and scratches
Produces crosshatch pattern
(Goodheart-Willcox Publisher)

40. Installing Press-Fit Dry Sleeves
Measure cylinder diameters
(Goodheart-Willcox Publisher)

41. Installing Press-Fit Dry Sleeves (cont.)
Measure outside diameter of cylinder sleeve
(Goodheart-Willcox Publisher)

42. Installing Press-Fit Dry Sleeves (cont.)
Heat cylinder block
Pack sleeve with dry ice
Coat sleeve with lubricant
Drive sleeve into cylinder
Machine top of sleeve flush with deck
Boring bar with face tool

43. Installing Wet Cylinder Liners
Clean mating and sealing surfaces
Install and lubricate new seals
Remove twists
Parting line parallel to groove
(Mack Truck, Inc.)

44. Inserting the Liner
(Mack Trucks, Inc.)

45. Inserting the Liner (cont.)
(Mack Truck, Inc.)

46. Counterbore Depth and Shims
Recut depth if cylinder block deck was resurfaced
Use shims to re-establish flange height
(Mack Truck, Inc.)

47. Installing a Fire Ring Gasket
(Goodheart-Willcox Publisher)

48. Crimping Beads Machined into liner flanges Promote sealing
(Goodheart-Willcox Publisher)