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5 Engine Blocks. 5 Engine Blocks Learning Objectives Explain how to gain access to the components in a stationary engine. Explain how to remove a mobile.

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Presentation on theme: "5 Engine Blocks. 5 Engine Blocks Learning Objectives Explain how to gain access to the components in a stationary engine. Explain how to remove a mobile."— Presentation transcript:


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)

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