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AT 181 - Block, Crank, and Pistons worksheet. Names ________________________________________________________________ Date _______________________
Measuring Deck Warpage
Upon completion of this job sheet, you should be able to properly inspect and measure the engine block deck for warpage. ASE Correlation This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Visually inspect engine block for cracks, corrosion, passage condition, core and gallery plug holes, and surface warpage; determine necessary action. Tools and Materials Straightedge Feeler gauge Engine block Procedure Using the engine you have disassembled and the proper service manual, you will identify and perform the required steps to inspect and measure the engine block deck for warpage. 1 1. Specification for maximum warpage allowed. _______________________ 1 2. Special tools required to perform this procedure? 1 3. Make sure the deck surface is clean. Task Completed □ 1 4. Note any damage (nicks, scratches, etc.) to the deck surface.
1 5. Actual warpage measurement. Left bank _________________ Right bank _____________ 1 6. Based on your findings, what is your recommendation?
Instructor’s Response __________________________________________________________
Inspecting and Measuring the Cylinder Walls
Upon completion of this job sheet, you should be able to properly inspect and measure the cylinder walls for wear. ASE Correlation This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Inspect and measure cylinder walls; remove cylinder wall ridges; hone and clean cylinder walls; determine need for further action. Tools and Materials Dial bore gauge Engine block Procedure Using the block from the engine you have disassembled and the proper service manual, you will identify and perform the required steps to inspect and measure the cylinder walls for wear. 1 1. Do any of the cylinders have visible signs of wear or damage? □ Yes □ No If YES, which one(s)?
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1 2. Is the cross-cut pattern still visible on all cylinder walls? □ Yes □ No If NO, on which ones is it no longer visible?
1 3. What is the specification for the bore? _____________________ 1 4. At what location in the cylinder is the bore measurement to be taken?
1 5. What is the specification for the maximum amount of taper? _________________ 1 6. At what locations in the cylinder is the taper measured?
1 7. What is the specification for the maximum amount of out-of-round? _________________
1 8. At what location in the cylinder is out-of-round measured?
1 9. Measure each cylinder at the locations required, and record your results. Bore Taper Out-of-Round Cylinder 1 _____ _____ ___________ Cylinder 2 _____ _____ ___________ Cylinder 3 _____ _____ ___________ Cylinder 4 _____ _____ ___________ Cylinder 5 _____ _____ ___________ Cylinder 6 _____ _____ ___________
- Put an * (or more than one if necessary) in the chart above to indicate any readings that are out-of-specification. Task Completed □
- Have the cylinders been bored to an oversize? □ Yes □ No If YES, what size? ___________________________________________________
- Based on your readings, what is your recommendation?
Instructor’s Response __________________________________________________________
Inspecting and Measuring Main Bearing Bore Alignment
Upon completion of this job sheet, you should be able to properly inspect and measure the main bore alignment. ASE Correlation This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Inspect and measure main bearing bores and cap alignment and fit. Tools and Materials Straightedge
1 2. Visually inspect each connecting rod for damage, bend, cracks, nicks. Record results. Piston number 1 ____________________________________________________________ Piston number 2 ____________________________________________________________ Piston number 3 ____________________________________________________________ Piston number 4 ____________________________________________________________ Piston number 5 ____________________________________________________________ Piston number 6 ____________________________________________________________ 1 3. Remove the rod bearings and keep them in order for later inspection. Task Completed □
- Clean the big end bore; note any visible issues, and measure the diameter and for out-of-round. Record results: Rod number 1 ______________________________________________________________ Rod number 2 ______________________________________________________________ Rod number 3 ______________________________________________________________ Rod number 4 ______________________________________________________________ Rod number 5 ______________________________________________________________ Rod number 6 ______________________________________________________________
- Remove the piston rings using a ring expander and be careful not to scrape the sides of the pistons. Lay to the side for later inspection. Clean the ring grooves using a ring groove cleaner. Task Completed □
- Visually inspect the piston ring grooves, ring lands, piston heads, and piston skirts for excessive scuffing. Record results: Piston number 1 ____________________________________________________________ Piston number 2 ____________________________________________________________ Piston number 3 ____________________________________________________________ Piston number 4 ____________________________________________________________ Piston number 5 ____________________________________________________________ Piston number 6 ____________________________________________________________
- Locate the manufacturer’s service information for where to measure piston diameter. Record that procedure:
- Measure the piston diameter and compare it to specifications. Record results: Piston number 1 diameter __________________ Within specification? □ Yes □ No Piston number 2 diameter __________________ Within specification? □ Yes □ No Piston number 3 diameter __________________ Within specification? □ Yes □ No Piston number 4 diameter __________________ Within specification? □ Yes □ No Piston number 5 diameter __________________ Within specification? □ Yes □ No Piston number 6 diameter __________________ Within specification? □ Yes □ No
- Hold one piston assembly and feel for free movement of the connecting rod. Place a shop rag around the connecting rod and place it in a vise. Push up and down on the piston to feel for even the slightest vertical movement. It should move sideways freely. Repeat for each piston and rod assembly. Note your results:
Piston number 1 ____________________________________________________________ Piston number 2 ____________________________________________________________ Piston number 3 ____________________________________________________________ Piston number 4 ____________________________________________________________ Piston number 5 ____________________________________________________________ Piston number 6 ____________________________________________________________
- If any pistons felt loose on the rod and your shop has the proper press and piston pin adaptor, remove those pistons from the rod. Does your shop have the proper equipment to remove the piston? □ Yes □ No
- If your shop does not have the proper equipment, have your instructor check your work now.
- If you have the equipment, note or mark the orientation of the piston on the rod. Set the piston and pin press adaptor on the vise. Be certain the piston and press rod are aligned properly. You must have safety glasses on. Press the pin from the piston and connecting rod. Repeat for as many piston assemblies as required. If the piston pins are full floating, simply remove the snap rings and push the pins out. Did you successfully remove the pin(s)? □ Yes □ No
- Set the piston and connecting rod aside. Visually inspect the piston pin for wear and measure its diameter. Record your results: Pin number 1 visual condition and diameter: _____________________________________ Pin number 2 visual condition and diameter: _____________________________________ Pin number 3 visual condition and diameter: _____________________________________ Pin number 4 visual condition and diameter: _____________________________________ Pin number 5 visual condition and diameter: _____________________________________ Pin number 6 visual condition and diameter: _____________________________________
- Compare the pins to specification. Which, if any, are worn? ________________________
- Inspect the connecting rod and piston bore for signs of wear. Measure the connecting rod bore using an inside micrometer or a dial bore gauge. Compare the bore to specifications. (On some piston assemblies, it will also be necessary to measure the bore in the piston; perform the work as specified in the service information.) Record results: Bore number 1 diameter ______________________ Within specifications? □ Yes □ No Bore number 2 diameter ______________________ Within specifications? □ Yes □ No Bore number 3 diameter ______________________ Within specifications? □ Yes □ No Bore number 4 diameter ______________________ Within specifications? □ Yes □ No Bore number 5 diameter ______________________ Within specifications? □ Yes □ No Bore number 6 diameter ______________________ Within specifications? □ Yes □ No
- Describe any work necessary to repair improper piston to rod fit. Record results: Piston number 1 ____________________________________________________________ Piston number 2 ____________________________________________________________ Piston number 3 ____________________________________________________________ Piston number 4 ____________________________________________________________ Piston number 5 ____________________________________________________________ Piston number 6 ____________________________________________________________ Instructor’s Response __________________________________________________________
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Rod bearing indications:
Corrective actions:
Instructor’s Response __________________________________________________________
Installing the Piston Rings
Upon completion of this job sheet, you should be able to properly install piston rings. ASE Correlation This job sheet is related to ASE Engine Repair Test content area: Engine Block Assembly Diagnosis and Repair; tasks: Inspect, measure, and install piston rings. This job sheet is also related to ASE General Engine Diagnosis; Removal and Reinstallation (R&R) tasks: Research applicable vehicle service information. Tools and Materials Ring expander Feeler gauges Procedure Your instructor will provide you with a specific engine. Write down the information, and then perform the following tasks: 1 1. Locate the correct rings for your engine. Look up the correct installation of the ring gaps and draw a diagram showing it below:
Installing the Piston Rings (continued) 1 2. Look up the specification for ring side clearance and for ring end gap. Record results: Ring side clearance specification: ______________________________________________ Ring end gap specification: ___________________________________________________ 1 3. Place an oil ring in the cylinder where indicated by the service information or toward the bottom of ring travel and square it with a piston. Measure the end gap. Place the second ring in the cylinder and measure the end gap. Place the top ring in the cylinder and measure the end gap. Repeat for all cylinders. Record results: Cyl. #1: oil gap _______________ Second gap _______________ Top gap _________________ Cyl. #2: oil gap _______________ Second gap _______________ Top gap _________________ Cyl. #3: oil gap _______________ Second gap _______________ Top gap _________________ Cyl. #4: oil gap _______________ Second gap _______________ Top gap _________________ Cyl. #5: oil gap _______________ Second gap _______________ Top gap _________________ Cyl. #6: oil gap _______________ Second gap _______________ Top gap _________________ 1 4. Are any gaps too wide? □ Yes □ No What, if anything, will you do to correct this?
Are any gaps too narrow? □ Yes □ No What, if anything, will you do to correct this?
1 5. Lubricate piston number 1. Install the oil ring, expander, and second oil ring by hand, being careful not to twist them excessively. Use a ring expander to properly install the second ring. Is there a top marking? □ Yes □ No Use a ring expander to properly install the top ring. Is there a top marking? □ Yes □ No Repeat for all pistons. 1 6. Measure ring side clearance for the oil, second, and top rings as specified. Repeat for each piston. Record results: Piston #1 oil clearance __________ Second clearance ___________ Top clearance ___________ Piston #2 oil clearance __________ Second clearance ___________ Top clearance ___________ Piston #3 oil clearance __________ Second clearance ___________ Top clearance ___________ Piston #4 oil clearance __________ Second clearance ___________ Top clearance ___________ Piston #5 oil clearance __________ Second clearance ___________ Top clearance ___________ Piston #6 oil clearance __________ Second clearance ___________ Top clearance ___________
- Space the gaps as instructed on each piston. Task Completed □ Instructor’s Response __________________________________________________________
- Correct any oil clearances to specifications as needed. Task Completed □
- If the rear main seal is a two-piece lip seal, install the pieces into the block and rear cap. Which direction must the lip of the seal face?
- Lubricate the inside surfaces of the bearing inserts with a film of engine oil. Task Completed □
- Install the crankshaft, caps, and bolts. Apply anaerobic sealer between the rear cap and cylinder block (if needed). Task Completed □
- Place the main bearing caps over the crankshaft journals, starting at the rear journal and working toward the front of the engine, making sure the correct cap is installed in the correct location and in the proper direction. Task Completed □
- Register the main bearing caps by tightening the cap bolts by hand while rotating the crankshaft. Task Completed □
- With the main bearing cap bolts fingertight, pry the crankshaft back and forth to align the thrust bearing. Task Completed □
- Rotate the crankshaft. Does it rotate freely with no binding or restrictions? □ Yes □ No If NO, correct any problems before continuing.
- What is the torque specification for the main bearing cap bolts?
- In the space below, draw the torque sequence for the main bearing cap bolts.
- Torque the bolts of the first cap in sequence to the specified value. Task Completed □
- Check crankshaft rotation by rotating it with a torque wrench. Note the amount of torque required to rotate the crankshaft during several revolutions.
- Torque the next cap in the sequence, and check the rotating torque of the crankshaft again. Task Completed □
- Continue to torque the cap bolts in sequence, making sure to check rotating torque after each cap is tightened. Record the turning torque of the crankshaft for the remaining caps below.
- Were there any large increases in the torque required to rotate the crankshaft?
□ Yes □ No If YES, stop and locate the cause of the problem.
- With all cap bolts properly torqued, check the rotating torque of the crankshaft. Specification _____________ Actual _________________
- If the engine uses a one-piece lip seal, install it. Task Completed □
- Check crankshaft end play. Specification _____________ Actual _________________ Instructor’s Response __________________________________________________________
