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36 Cards in this Set
- Front
- Back
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Casting processes for blocks |
Sand cast, Die cast, Lost Foam cast |
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Engine block material |
Cast Iron, Aluminum |
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Engine Block has what functions? |
Rigid foundation for all major components, also provides mounting points for accessories |
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Strongest part of an engine |
Crank case / main bearing webs |
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Types of bearing caps |
Two, four, crossbolt and mono block |
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How are oil galleries created in cast blocks? Why are they made that way? |
Drilled, provides a smooth uniform hole with no restrictions. No sand left over from casting |
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How are coolant passages and oil galleries closed after the sand is removed from the block? |
Expansion (frost) plugs (coolant) and threaded plugs (oil) |
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Open decks move the head bolts away from the cylinders to prevent |
Distortion from torquing the head on |
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What are the 3 block types in regards to liners and design |
One piece with integral cylinders, one piece with liners, multipiece blocks |
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What is a good indication that the block is a multipiece you can see easily on service? |
Aluminum oil pan |
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What is the main advantage of multipiece block design? |
Reduces NVH (noise, vibration, harshness) and increased bottom end rigidity |
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What are 3 types of sleeves/liners used in engines? |
Wet liner, dry liner, repair sleeves |
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Dry liners can be secured in the block in what two ways? From manufacturer |
Interference fit, cast in place |
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What methods of block cleaning are there? |
Pressure washer, cold tank(petroleum solvent), hot tank(caustic solution), mechanical parts washer, and high Temp oven |
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What's the best way to clean a block? |
High Temp oven (cleans rust and scale aswell) |
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What block cleaning method should NOT be used on Aluminum blocks? |
Hot tank (caustic solution) it will eat the block |
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After cleaning oil galleries with a brush and water what should you do to finish the process? |
Blow them out with compressed air |
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What are 4 methods of crack detection? |
Dye check, magnetic particle, fluorescent magnetic (mangaflux), and pressure test |
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After cleaning a block what should be done to the threads around the cylinder block? |
clean with air, inspected, then chase threads |
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What should you not clean machined surfaces when removing old gaskets? |
Air grinder with abrasive pads |
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When checking the cylinder block for surface flatness, what tools do you use? |
Straight edge and feeler gauges |
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What's the maximum a cylinder block can be out in terms of flatness? (Bills test answer) |
.004" max |
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What's the minimum amount of places to check flatness on a cylinder block? (Q 46 midterm) |
Minimum 3 but manufacturers recommend 5 |
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What's the maximum out of alignment the bearing bores can be? |
.001" (bill) // check manufacturers spec (ILM) |
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How many locations should you measure a main bearing bore for out of round? |
3 places, not on the parting line |
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Most cylinder wear occures at |
90° crank centreline, top of piston ring travel |
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What areas are 90° crank centreline in the cylinders? |
Major and Minor thrust sides |
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On the compression stroke the piston is against what side of the cylinder? |
Minor thrust side |
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On the combustion stroke what side of the cylinder is the piston against? |
Major thrust side |
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What wear are you measuring for in a cylinder if you take a measurement at the top of ring travel and at the bottom under ring travel 90° to crank centreline |
Cylinder taper wear (mid/final Bill guarantee) |
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If you take 2 measurements, 90° from eachother at the top of ring travel in the cylinder, what are you measuring? |
Cylinder out of round (mid/final Bill guarantee) |
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Cylinder bores that are worn past manufacturers spec must be ___? |
Bored over sized |
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What formula do you use to determine out of round? |
A-B= out of round. Subtract the smaller from the larger number to get out of round |
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What formula do you use to determine taper? |
A-B= taper. Subtract the smaller number from the bigger number normally top-bottom= taper |
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What are two methods of thread repair and what one is okay to use on cylinder heads? |
Solid type and helicoil repair threads, only solid type can be used on heads as helicoil isn't strong enough for the torque process |
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When boring a cylinder oversize what formula do you use to determine the amount of oversize? |
Taper x 2 + 0.010"(0.25mm) remember pistons aren't made in all sizes, go to next piston size up that fits |
