TTEC4842- AUTOMOTIVE ENGINES (ENGINE SHORT BLOCK)

                           TTEC4842- AUTOMOTIVE ENGINES 
                        
                             ENGINE SHORT BLOCK    

                                      

(Enigne short block)

Firstly I, started taking everything apart from the block pistons, conrods, crankshaft,etc and opened the block.

INSPECTION OF PISTONS:

There was no piston damage to 4 pistons but the one thing ws, the piston 2,3,4 were missing there middle rings.

	1	2	3	4
piston	78mm	78.01mm	78.01mm	78.01mm
ok/fail	ok	ok	ok	ok

This showed me that the pistons were all ok within the specs ., and dont need any replacement.

Inspection of cylinder bore:

During the inspection of the bore, I found there were no damages on it ,but there were few scuffs on all.

Then moved on by measuring the bores with a bore gauge at two positions top & bottem.

Cylinder bore measurement:

		cylineder 1	cylinder2	cylinder 3	cylinder 4
1	first measurement ( direction x)	78.01 mm	78.01mm	78.01mm	78.01mm
	first measurement ( direction y)	78.01mm	78.01mm	78.01mm	78.01mm
3	third measurement (x)	78.01mm	78.01mm	78.01mm	78.01mm
	third measurement (y)	78.01mm	78.01mm	78.01mm	78.01mm
	amount of taper	0.0mm	0.0mm	0.00mm	0.00mm
	amount of ovality	0.0mm	0.00mm	0.0mm	0.0mm
	ok/fail	ok	ok	ok	ok

 This showed me that the cylinder bore measurement meet the specifications.

Piston clearance:

		cylinder 1		cylinder 2	cylinder 3	cylinder 4
(a)	largest boren diameter	78.01mm	78.01mm		78.01mm	78.01mm
(b)	pistoon skirt diameter	78.00mm	78.01mm		78.01mm	78.01mm
	piston to cylinder clearance(a-b)	0.01mm	0mm		0.0mm	0.0mm
	ok/fail	ok	ok		ok	ok

 This showed me that all four pistons were in the manufacturing specifications.

Piston and rings:

Firstly I,did a visual check on the piston rings for any sign of damage, wear or breakage,.

four of the rings were in good condition, have 3 pistons missing middle rings.

Checking piston ring side clearance :

Then moved on by checking the clearance of the piston rings using a feeler gauge between the ring and the ring groove.

	Ring side clearance
	specification  0.030mm-0.065mm
1	0.038mm ok
2	0.038mm ok
3	0.038mm ok
4	0.038mm ok

 This showed us that the rings clearance is good and it meet the specification. if the rings have any excessive side clearance. if by if the lands wear our or the rings wear out aswell.

Checking piston ring end gap:

Here I,push the ring down the bore, using the piston to keep it square, until the ring is in the least worn part of the bore. then i checked the ring end gap with a feeler gauge.

	top ring end clearance
	specification  0.15mm  - 0.30mm
cylinder 1	0.33mm  ok
cylinder 2	0.33mm  ok
cylinder 3	0.33mm  ok
cylinder 4	0.33mm  ok

The pistons rings didnt require any replacement and they were in the manufactring specifications, CYL4 ring is slightly more then spec but doesnt matter.
Inspecting connecting rods:

first thing was is to inspect the rods for any bend twist or any misaligment. i checked my rods is by using the tool called hydrulic rod straightening press.

	bend	twist
1	0.813mm	0.885mm
2	0.0385mm	0.885mm
3	0.385mm	0.254mm

In this task we couldnt use our rods we used different rods and couldnt get the manufacturing specifications.

Inspecting the crankshaft:
main journal specification

diameter = 49.938-49.956mm

taper limit = 0.05mm

ovality= 0.05mm

In this task was to measure the main journal using a micrometer to check for (A) which is across and (B) down.

	1	2		3	4	5
diamater A1	49.45mm		49.44mm	49.45mm	49.44mm	49.44mm
diameter B1	49.44mm		49.44mm	49.44mm	49.43mm	49.48mm
diameter A2	49.46mm		49.44mm	49.44mm	49.44mm	49.49mm
diameter B2	49.44mm		49.44mm	49.44mm	49.44mm	49.49mm
ovality A minus B	0.01mm		0.0mm	0.0mm	0.01mm	0.00mm
largest diameter  A1 or B1	A1		A1	A1	A1	A1,B1
smallest diameter A2 or B2	B2		A2	B2	B2	A2
taper  A1 minus A2	0.01mm		0.00mm	0.00mm	0.00mm	0.01mm
STD diameter	49.45mm		49.46mm	49.496mm	49.49mm	49.49mm
smallest diameter (from A or B )	49.44mm		49.44mm	49.44m	49.43mm	49.48mm
wear	0.01		0.02mm	0.00mm	0.01mm	0.01mm

The undersize was 0.50mm that mean main journals were in the manufactring specification.

Big end journals:

big end journal specification

diameter = 39.94mm

taper limit = 39.94mm

ovality= 39.94mm

	1	2		3	4
diameter A1	40.70mm		40.70mm	40.70mm	47.70mm
diameter B1	40.94mm		4.94mm	40.93mm	40.94mm
diameter A2	40.93mm		40.94mm	40.94mm	40.93mm
diameter B2	40.94mm		40.94mm	40.94mm	40.93mm
ovality A minus B	0.24mm		0.24mm	0.23mm	0.24mm
largest diameter  A1 or B1	B1		B1	B1	B1
smallest diameter A2 or B2	A2		A2	B1	B1
taper  A1 minus A2	0.24mm		0.24mm	0.23mm	0.24mm
STD diameter	39.94mm		39.94mm	39.94mm	39.94mm
smallest diameter (from A or B )	40.93mm		40.94mm	40.93mm	40.94mm
wear	0.99mm		1mm	0.99mm	1mm

 This was a havey duty crank shaft , and the undersize 0.50mm this was in good condition and meet the specifications.

Inspecting the crankshaft:

crankshaft deflection specification. Runout 0.04mm.

Here I, put the crankshaft on the 'v' block to measure the crankshaft deflection. which i measured by using a dial test indicator (DTI)

The run out was 0.03mm there was distortion within specs..

Inspecting the cylinder block:

I,did a visual check on the block there was minear scuffS, REST ALL WAS GOOD.

The moved on by measuring the cylinder block face distortion in six places.

Block face distortion specification  :- 0.015mm

6 of the test on the block face distortion WERE AS FOLLOW:-

1. 0.038mm
2. 0.038mm
3. 0.038mm
4. 0mm
5. 0mm
6. 0mm

So, everything was within specs.

Inspection of timing gears, sprockets,chains,and belts.

1. Camshaft gears or sprockets= there was no damage or wear on the camshaft. ALL GOOD

2. Crank gear or sprockets= it was clean no wear , BUT THE CHIP ON CRANK GEAR BROKEN SO REPLACE IT

3. Idler gears or sprockets=  Rust on idler so replace it.

THE BELT IS WARN , SO NEED TO REPACE IT.

Inspect water pump:

EVERYTHING GOOD IN CONDION ,THEN BLADES HAVE RUST ON THEM.

Inspecting oil pump:

The type of oil pump i was working on was a rotory pump. i did a visual check, the rotor pump looks in good condition no damage or any signs of scuffing.

checking clearance

	specification	actual
SIDE CLEARANCE	0.025-0.075mm	.0051mm
ROTOR TIP CLEARANCE	0.060-0.180mm	.089mm
OUTER ROTOR CLEARANCE	0.080-0.180mm	.125mm

The oil pump is in good condition and its serviceable.

checking main bearing oil clearance:

first thing i did was placed a strip of plasti-gauge across each main journal


Main bearing clearanceThen i installed the bearing and caps to torque specification 54-59 mm
Then i removed the caps and bearing and measured the widest part of the plasti-gauge

specification 0.024-0.042mm
	1	2	3	4	5
oil clearance (actual)	0.025mm	0.025mm	0.025mm	0.038mm	0.038mm
ok/fail	ok	ok	ok	ok	ok

The oil clearance were in the specifications.

 checking crankshaft end play, using The (DTI) ; fIRSTLY  I, set the gauege to Zero and i pulled the crankshaft towards the DTI and i had reading of  0.2 there end play on the crankshaft but within specs.

checking crankshaft end play using the feeler gauge:
specifications'0.08-0.242
End play 0.09

This showed that the crankshaft is in good condition and meet the specification

checking the big end bearing clearance

i used the same meathod for the main bearing by using a plasti-gauge across the connecting rod journal.

specification 0.028-0.050mm
	1	2	3	4
oil clearance (actual)	0.050mm	0.050mm	0.50mm	0.050mm
ok/fail	ok	ok	ok	ok

the big end bearing clearance also meet within the specification. i ensured that the crankshaft also should turn freely before doing the measurments.

checking the connection rod end play, using a feeler gauge.

specification -0.30mm
	1	2	3	4
con-rod-endplay (actual)	0.28mm	0.28mm	0.28mm	0.28mm
ok/fail	ok	ok	ok	ok

WITHIN SPECS SO NO CHANGE NEEDED HERE.

IN LAST I,WILL LIKE TO SAY THAT THE BLOCK I WAS WORIKNG WITH WAS A HEAVY DUTY DUTY BLOCK THERE WAS NO DAMAGE ON THE PISTON BUT WERE MISSNG FEW MIDDLE RINGS, THE RODS WERE NICE AND STRAIGHT. THERE WERE FEW BOLTS MISSING ON THE ENGINE BEFORE I STARTED WORKING.