Ch5. Engine Blocks

Face tool

A boring bar with a face tool installed in the cutter head is used to machine the top of the sleeve flush with the deck.

Boring bar

A cutting tool used to perform boring operations

Cylinder liner

A liner or sleeve interposed between the piston and the cylinder wall or water jacket to provide an easily replaceable surface for the cylinders

Galleries

A pathway for oil or coolant inside a block, cylinder head, etc.

Dry liner

A replacement cylinder liner that does not move in direct contact with the coolant

Firering

A ring that is located next to the liner bore in the top of the flange. Greatly reduces the likelihood that the head gasket will be burned by the heat of combustion

Joint sealing compound

A seal that you have to coat parts with before reinstalling

Porous chromium

A simple and more efficient process is provided for producing deep, non-connected pit type, porous chromium surfaces with more constant and uniform characteristics. A substrate is initially electroplated with an excess of chromium having predetermined physical and chemical properties.

Shims

A thin piece of brass, steel, or plastic inserted between two parts to adjust the distance between them.

Ridge reamer

A tool used to remove the metal lip on top of the cylinder walls caused by engine wear

Airless shot blasting

Airless shot blast equipment utilizes cast steel shot or grit, as well as other types of abrasive media, and is used for metal cleaning, removal of paint, rust, mill scale, sand, ceramic and shell removal from diecastings, steel and iron castings, or investment castings, metal surface preparation prior to paint or coating, automotive parts remanufacturing and shot peening for metal fatique life and stress relief.

Air inlet ports

Allow air to enter. Two stroke Diesel engines have cylinder liners that contain air inlet ports

Flange fretting

Also known as Breakage

Crimping beads

Also known as coining beads. Often machines into liner flanges to promote sealing between the liner and the head gasket. Narrow rings located on the top side of the flange.

Ridge

Also means wear. Check for ridge near the top of the piston ring travel zone. After extensive engine operation, the cylinder surface will wear in the area where the rings make contact

Thermal cleaning ovens

Become popular in diesel shops. Main advantage of this system is that it reduces the oil and grease on and in engine blocks, cylinders heads, and other parts

Cylinder Assembly

Completes the structural framework of an engine. As one of the main stationary parts of an engine, the cylinder assembly, along with various related working parts, serves to confine and release the combustion gases

Shutterstat

Controls the radiator shutters

Deck warpage

Cylinder heads and blocks may need to be resurfaced to restore flatness or to improve the surface finish, or milled to change the deck height for a variety of reasons. The deck surface on the head or block may need to be resurfaced if the surface isn't smooth or flat.

Deck height

Distance from the crankshaft centerline to the block deck

Wet liner

High combustion temperatures are dissipated through the liner walls directly into the water jacket. These liners usually have a close fit between the outside flange diameter and the upper inside diameter of the cylinder block counterbore.

Counterbore depth

If a cylinder block deck is resurfaced, the cylinder block counterbore depth must be recut to specifications. If the cylinder block deck had not been resurfaced, but there is excessive pitting or erosion of the cylinder block counterbore, recut the counterbore as required

Welded construction

In this type of construction, the block is usually fabricated of forgings and/or steel plates that are welded together

Cylinder block

Largest single component of the modern Diesel engine. Essentially the framework of the engine. Nearly all engine parts are connected to the cylinder block in some way

Lower press fit liner

Liners that have a press fit just below the blocks counterbore

Water jacketed liner

Liners with integral cooling passages

Close-grained cast iron

Material most commonly used for liner construction

Mobile engine

Must be removed and disassembled to service many of the components

Cylinder liner puller

Must be used to remove most liners. Some liners require the use of a hydraulic puller

Flange height

Of liner exceeds out-of-round or taper limits, is worn excessively, or if the flange height above the deck is not within specifications, the liner should be removed.

Piston slap

Piston slap is the rocking of the piston in the cylinder (as opposed the desired movement of the piston up and down the cylinder). It happens when there is "too much" room for the piston in the cylinder and the skirt of the piston hits the cylinder wall.

Liner cavitation

Pitting on the outside diameter

Honing

Process of removing metal; with a fine abrasive stone. Used to achieve close tolerances.

Access covers

Removable plates that allow access to parts of an engine, such as the camshaft or lifter gallery

Deglazing

Removing the glaze from cylinder walls before new piston rings are installed

Point welding

Resistance spot welding is a process in which contacting metal surface points are joined by the heat obtained from resistance to electric current. It is a subset of electric resistance welding. Work-pieces are held together under pressure exerted by electrodes

Stationary engines

Serviced on location and not removed from their installation.

Cylinder boring

Should be done only by a machinist. Bored out means the cylinder becomes wider in diameter, but the cylinder walls become thinner. Stroked means that the crankshaft is changed so that the piston travels further within the cylinder.

Rust preventive solution

Solution to keep something from rusting

Explosion doors

Spring loaded panels installed on large displacement Diesel engines that also act as a pressure relief in the event of a crankcase explosion or extreme pressure build up within the crankcase

Integral cylinder bore

The cylinder walls in which a piston moves back and forth may be an integral part of the cylinder block or may be formed by a separate sleeve or liner. The integral cylinder bore cannot be replaced. Also known as the enbloc or parent bore. When excessive wear occurs in a cylinder of this type, then it must be rebored and honed. If wear is too excessive, the block may be sleeved or replaced

Inhibited acid compounds

The use of inhibited acid compounds to remove scale from the water jacket may help loosen the liner.

One piece construction

This type of block is formed by outing iron or aluminum into an appropriate sand mold

Counterbore

To enlarge a hole to a given depth

Sealing rings

Two are recessed in the cylinder block. Used to prevent leaks between the liner and the block

Emulsion type cleaning solution

Used to clean aluminum parts

Plateau honing

Used to remove the peaks and valleys, leaving flatter plateaus that cause less ring wear during break in

Parting line

Usually visible in the center of the outside diameter of the seal. Should be parallel to the groove when the twist is eliminated

Crankcase

a case or covering enclosing a crankshaft

Crosshatch pattern

pattern created by the series of overlapping strokes. Angled to prevent the rings from catching in the grooves

Chemical cleaning

relies primarily on chemical action to remove dirt, grease, scale, paint or rust. Hot alkaline tank cleaning is a chemical cleaning method often used on cast iron blocks