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Chapter 5 Engine Blocks Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Learning Objectives Explain how to.

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Presentation on theme: "Chapter 5 Engine Blocks Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Learning Objectives Explain how to."— Presentation transcript:

1

2 Chapter 5 Engine Blocks

3 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Introduction This chapter describes: –Cylinder blocks –Accessing diesel engine components –Cleaning engine blocks –Inspecting cylinder blocks –Installing cylinder liners

6 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Cylinder Blocks Stationary diesel engines –Welded construction Mobile engines –One-piece construction –Galleries (Great Lakes Energy Systems, Inc.)

7 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Accessing Components in a Mobile Engine Removed and disassembled for service Procedure varies –Check service manual (Mack Trucks, Inc.)

9 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Engine Disassembly Remove accessory components Remove rocker arm covers (Cummins Engine Co., Inc.)

11 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Injectors (Goodheart-Willcox Publisher)

12 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Cylinder Head (Cummins Engine Co., Inc.)

13 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Cam Follower Housing (Cummins Engine Co., Inc.)

14 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Flywheel (Cummins Engine Co., Inc.)

15 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Oil Pan (Cummins Engine Co., Inc.)

16 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Rear Main Seal Plate (Cummins Engine Co., Inc.)

17 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing the Camshaft Cover (Cummins Engine Co., Inc.)

18 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Cleaning the Cylinder Liners (Cummins Engine Co., Inc.)

19 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Piston Assembly Removal (Cummins Engine Co., Inc.)

20 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Piston Assembly Removal (cont.) (Cummins Engine Co., Inc.)

21 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Crankshaft Removal Use hoist Place in V-block (Cummins Engine Co., Inc.)

22 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Engine Block Cleaning Remove oil gallery plugs and freeze plugs Cleaning methods –Chemical –Thermal (Cummins Engine Co., Inc.)

23 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Thermal Cleaning Ovens Reduces oil and grease on parts Ash removed by airless shot blasting (Am/Pro Machinery, Inc.)

25 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Cylinder Block Inspection Perform visual inspection Replace parts as necessary Coat parts with joint sealing compound before reinstallation (Cummins Engine Co., Inc.)

26 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Inspecting Cylinder Bores and Liners Visual inspection –Wear –Point welding Piston slap (Goodheart-Willcox Publisher)

29 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Checking for Cylinder Taper (Goodheart-Willcox Publisher)

30 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing Ridges Check for ridges Remove using ridge reamer Blend cut for smooth surface (Cummins Engine Co., Inc.)

31 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Checking the Counterbore (Goodheart-Willcox Publisher)

32 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Dry Liners (Goodheart-Willcox Publisher)

34 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Wet Liners (Goodheart-Willcox Publisher)

35 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Types of Wet Liners Lower press fit liners Reduce –Liner cavitation –Flange fretting Integral cylinder liners

36 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Removing Cylinder Liners Use cylinder liner puller Use inhibited acid compounds if puller cannot free liner (Mack Trucks, Inc.)

37 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Cylinder Boring Done only by machinists Process is same for integral bores and cylinder liners

38 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Cylinder Honing Eliminates peaks and valleys in wall surface Progressive process –Coarse honing –Plateau honing (Goodheart-Willcox Publisher)

39 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Deglazing Cylinder Walls Removes scuffs and scratches Produces crosshatch pattern (Goodheart-Willcox Publisher)

40 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Installing Press-Fit Dry Sleeves Measure cylinder diameters (Goodheart-Willcox Publisher)

41 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Installing Press-Fit Dry Sleeves (cont.) Measure outside diameter of cylinder sleeve (Goodheart-Willcox Publisher)

42 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. 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 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Inserting the Liner (Mack Trucks, Inc.)

45 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Inserting the Liner (cont.) (Mack Truck, Inc.)

46 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Counterbore Depth and Shims Recut depth if cylinder block deck was resurfaced Use shims to re- establish flange height (Mack Truck, Inc.)

47 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Installing a Fire Ring Gasket (Goodheart-Willcox Publisher)

48 Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website. Crimping Beads Machined into liner flanges Promote sealing (Goodheart-Willcox Publisher)


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