Lap 4: repairing and testing cylinder block component
Engine pluck: It is one of the most important parts of the engine, as it contains a
special identification number for each engine, and the rest of the engine
components are assembled on it.
shapes of engine block:
1: line engine
2: V engine
3: W engine
4: H engine
Cylinder block component
1: cylinder (the channel in which the piston moves)
2: Water jacket (which cool the engine intake)
3: Oil channels (which serve to deliver oil to the upper parts of the engine, such as
the head)
4: The crankshaft installation location
5: Motor head fixing screws
6: Locations for installing motor outer component
Engine block testing:
1: Check the flatness of the engine block surface
Before starting to check the levelness of the engine surface, it must be cleaned well
To facilitate the detection of cracks or fractures in the motor casting that prevent its
use or make it need welding
* The levelness check of the engine block surface is carried out in a similar manner
as the engine head levelness check
The flatness of the surface of the
engine block is checked using a
measuring ruler in addition to the
filler gage, where the ruler is placed
on the face of the pouring in three
shapes (a diagonal, an opposite
diagonal, and a third straight) as
shown in the figure
Maximum variation allowed is
(0.05mm to 0.1mm)
Q: Why is the amount of wicking allowed in the surface of the engine block more
than the surface of the head of the engine knowing that both of them form the
combustion chamber and an important factor in maintaining the efficiency of the
engine’s work?
2: cylinder test
Engine cylinders are the most vulnerable part to cracks due to the temperature
differences that affect them
Engine cylinders are divided into two parts
1: Dry Cylinders: They are separated from the coolant by the engine’s inlet wall
* This type of cylinder can only be changed by turning process
2: Wet cylinders: They are those that have no separator between them and the
coolant
* This type of cylinder can be changed without the need for lathing
Test:
1: Check the shape of the engine cylinders
* The shape of the engine cylinders must be cylindrical in shape, and if it turns into
an oval shape, it needs to be changed
2: Examination of the external cracks on the surface of the cylinders
3: Checking the surface smoothness of the cylinders
3: Check crankshaft bearings
* * Before disassembling the crankshaft, the crankshaft fixing bits (bearings) must
be numbered to return them to their original positions before disassembly. Why?
The numbers of the bearing sheal
the measurements of the bearing
sheal range from (0.1 mm) to (1
mm) and are written on the body of
the horns as shown in the following
picture
**must be check for no groves in bearing sheal
Check the axiality of the crankshaft bearings
Before checking the axial thrust bearings must be thoroughly cleaned
* The axiality of the crankshaft bearings should not exceed 0.05 mm, and if it is
increased, a lathing must be made for the engine shaft or replaced.
The crankshaft axial check is carried out in two stages
The first stage is to make sure
that the bearings are straight and
straight
The second stage is measuring
the inner diameters of the
crankshaft axes
Tests for crankshaft
The crankshaft is the backbone of
the engine, which converts the
movement from reciprocating to
circular, and regulates the engine's
work according to different
operating conditions
.
1: Examine the crankshaft for cracks or irregular wear in the crankshaft
2: Check the straightness of the
crankshaft
* The oil clearance in the
crankshaft and bearings should
not exceed 0.05 mm for gasoline
engines and 0.06 mm for diesel
engines.
piston and conrods tests:
summary of component
1 - 30 Nm + torque a
further 90°(1/4tur)
2 - Conrod bearing cap
**as a result of the con‐
rods separated in the
cracking process, the
conrod bearing cap fit
sonly in one position and
only to the relevant con‐
rod
3 - Bearing shells
4 – Conrod
5 – Circlip
6 - Piston pin
7 – Piston
** Mark the installation
position and the
assignment to cylinder
8 - Piston rings
* Compression rings
9 - Piston ring
* Oil scraper ring
Checking piston
Using an external micrometer, measure
pistons approx. 10 mm from the lower
edge of skirt, at 90° to the piston pin
axis.
** Maximum deviation from nominal
dimension: 0.04 mm
Measure piston ring end gap
1: Push the piston ring into the bottom
cylinder opening at right
angles to the cylinder wall from above
to about 15 mm from
the cylinder edges.
2: To insert, use a piston without
piston ring.
Measure piston ring vertical gap:
Clean before inspecting the annular
groove of the piston
Q: What do we mean by the following terms
المحرك مجشنط
المحرك مفرهل
المحرك بياكل زيت
فحص فتالن السكبة
فحص التسريب الداخلي
فحص شكل القميص
فحص استقامة لقم الثابت
المحرك بضغط
