Engine service : automotive machining and engine repair

1 CONTENTS SHOP SAFETY AND HAZARDOUS WASTE MANAGEMENT Li fling Hazards Accidents During Installation Respiratory Hazards in the Shop Substance Abuse in the Workplace General Safety Guidelines Handling Hazardous Materials Best Management Practices Summary Review Questions 2 FUNDAMENTALS OF MACHINING Machining Processes Tool Materials Cutting Tool Glossary Single Pointed Tools Milling Cutters Drills, Reamers and Other Drilling Tools Grinding and Honing Speeds and Feeds Machine Installation and Set-Up Correcting Alignments Between Centers Tramming Spindles Summary Review Questions 3 MEASURING TOOLS Understanding Specifications and Tole rances Calculating Thermal Expansion Comparing Units of Measurement Using Micrometers Making Transfer Measurements Using Dial Indicators Using Dial Bore Gauges U s ing Calipers Che cking Alignments Chapter-Page 1-1 1-2 1-3 1-4 1-4 1-8 1-10 1-12 1-14 2-1 2-4 2-6 2-6 2-9 2-11 2-15 2-16 2-18 2-20 2-23 2-24 2-25 3-1 3-3 3-4 3-5 3-8 3-10 3-10 3-1 2 3-1 2 Measuring Surface Finishes 3-13 Measuring Thicknesses of Castings 3-14 Summary 3-15 Review Questions 3-16 4 FASTENERS Determining the Strength of Fasteners 4-1 Comparing Clamping Force and Torque 4-3 Identifying Threads 4-3 Using Pipe Threads and Fittings 4-4 Removing Broken Fasteners 4-5 Installing Helicoils 4-6 Removing Broken Tools 4-8 Summary 4-8 Review Questions 4-9 5 ENGINE THEORY The Four-Stroke Cycle 5-1 Compression Ignition Engines 5-3 Variable Valve Timing and Valve Action 5-6 Valve Train Configurations 5-7 Valve Lifters and Lash Compensators 5-9 Engine Oiling 5-12 Engine Oils 5-15 Engine Measurements 5-20 Fits and Clearances 5-22 Cooling System Operation 5-23 Combustion Efficiency 5-24 Summary 5-26 Review Questions 5-27 6 ENGINE DIAGNOSIS Looking for Signs of Engine Wear 6-2 Checking the Block Assembly 6-2 Testing Power Balance 6-3 Testing Compression 6-4 Testing Cylinder Leakage 6-5 Checking Valve Timing 6-5 Testing Manifold Vacuum 6-7 Testing Exhaust Back Pressure 6-9 Testing With a Scan Tool; An Introduction Diagnosing Engine Noises Testing Engine Oil Pressure Testing Cooling systems Summary Review Questions 7 ENGINE DISASSEMBLY Hints for Disassembly in the Chassis Disassembling Cylinder Heads Numbering Connecting Rods Ridge Reaming Removing Piston and Rod Assemblies Removing the Timing Chain and Sprockets Removing the Crankshaft Removing Cams, Lifters and Followers Removing Camshaft Bearings Removing Oil Plugs and Core Plugs Summary Review Questions 8 CLEANING ENGINE PARTS Using Solvent and Cold Solutions Cleaning in Hot Tanks Degreasing in Ovens Using Airless Shot Blasters Bead Blasting Blasting With Baking Soda Blasting With High Pressure Water Tumbling Small Parts Using Hand and Power Tools Removing Rust and Scale Working Under Regulations Summary Review Questions 9 INSPECTING VALVE TRAIN COMPONENTS Determining Valve Guide Wear Checking Valves 6-10 6-12 6-14 6-15 6-16 6-17 7-1 7-2 7-4 7-5 7-6 7-7 7-7 7-8 7-9 7-10 7-12 7-13 8-2 8-2 8-3 8-4 8-4 8-5 8-6 8-6 8-7 8-8 8-8 8-10 8-11 9-1 9-2 Checking Natural Gas Valve Trains 9-4 Testing Valve Springs 9-5 Inspecting Camshafts, Lifters, and Followers 9-6 Inspecting Rocker Arms and Pushrods 9-10 Checking Timing Chains and Gears 9-12 Checking Cylinder Head Castings · 9-13 Summary 9-15 Review Questions 9-16 10 INSPECTING ENGINE BLOCK COMPONENTS Measuring Cylinder Wear 10-1 Measuring Piston Clearance 10-3 Checking Pistons 10-3 Checking Piston Pin Clearances 10-5 Checking Cylinder Block Flatness 10-6 Measuring Main Bearing Bores 10-6 Checking the Crankshaft 10-7 Measuring Connecting Rod Bores 10-9 Summary 10-10 Review Question~ 10-11 11 CRACK DETECTION AND REPAIR Using Dry Magnetic Particle.Inspection 11-1 Using Wet Magnetic Particle Inspection 11-2 Using Dye Penetrants 11-3 Pressure Testing Castings 11-3 Using Crack Repair Pins 11-4 Stop Drilling 11-11 Welding Head and Block Castings 11-12 Sealing Castings I 1-14 Summary 11-15 Review Questions 11-17 12 RECONDITIONING VALVE TRAIN COMPONENTS Removing and Replacing Valve Guides 12-1 Knurling Valve Guides 12-3 Fitting Oversized Valve Stems 12-6 Replacing Integral Valve Guides 12-6 Refacing Valves and Valve Stems 12-12 Grinding Valve Seats 12-14 Cutting Valve Seats Installing Valve Seats Fitting Valve Seals Replacing Rocker Arm Studs Correcting Installed Spring Height Correcting Installed Stem Height Refacing Rocker Arms Straightening Aluminum Heads Correcting Overhead Camshaft Centerlines Regrinding Camshafts, Lifters, and Followers Summary Review Questions 13 RECONDITIONING ENGINE BLOCK COMPONENTS Honing Cylinders for Overhaul Piston Inspection and Knurling Reboring and Honing Cylinders Sleeving Cylinders Line Boring and Honing Fitting Piston Pins Resizing Connecting Rod Housing Bores Assembling and Aligning Pistons and Connecting Rods Regrinding and Polishing Crankshafts Removing and Replacing Crankshaft Reluctor Rings Overhauling Oil Pumps Summary Review Questions 14 RESURFACING CYLINDER HEADS AND BLOCKS Comparing Resurfacing Machines General Precautions Correcting V-Block Intake Manifold Alignment Determining V-Block Ratios Resurfacing Overhead Cam Cylinder Heads Resurfacing Diesel Cylinder Heads Resurfacing Air Cooled Cylinder Heads Summary Review Questions 12-19 12-21 1 12-24 12-27 12-28 12-29 12-31 12-31 12-35 12-37 12-41 12-42 13-1 13-2 13-4 13-10 13-11 13-14 13-16 13-21 13-26 13-36 13-41 13-44 13-45 14-1 14-3 14-6 14-9 14-11 14-12 14-13 14-14 14-15 15 ENGINE BALANCING Weighing Pistons and Connecting Rods 15-3 Balancing Connecting Rods 15-4 Balancing Pistons and pins 15-4 Balancing Crankshafts 15-5 Balancing Flywheels and Clutches 15-10 Balancing Torque Converters 15-10 Balancing with Heavy Metal 15-11 Suggestions for Minimum Balancing 15-12 Summary 15-13 Review Questions 15-14 16 ENGINE ASSEMBLY Cleaning and Deburring for Assembly 16-1 Assembling Cylinder Heads 16-2 Installing Core Plugs 16-3 Installing Camshaft Bearings and Camshaft 16-4 Installing Oil Plugs 16-7 Sealing Rotating Shafts; the Basics 16-8 Fitting the Rear Main Seal 16-10 Installing the Main Bearings and Crankshaft 16-12 Setting Valve Timing 16-15 Installing Piston Rings 16-18 Installing Piston and Connecting Rod Assemblies 16-20 Assembling Cylinder Heads to Engine Blocks 16-21 Installing Rocker Arms 16-22 Adjusting Valves 16-23 Installing the Oil Pump 16-24 Pre-Oiling the Engine 16-25 Installing Timing Covers 16-26 Hints on Gaskets, Seals, and Sealants 16-27 Using an Assembly Checklist 16-28 Testing in a Run-In Stand 16-31 Assembling Flywheels and Flexplates 16-32 Attaching Bellhousings 16-33 Summary 16-34 Review Questions 16-35 17 PREPARING PERFORMANCE ENGINES Improving Efficiency . 17-2 I Improving Flow Through Ports Reducing Restriction at the Valves Flow Testing Improving Flow through Manifolds Extrude Honing Dealing with Tumble and Swirl Synchronizing Valve Opening and Piston Travel Maximizing Cylinder Pressure Selecting Camshafts Selecting Camshafts for Forced Induction Matching Intake Airflow to the Engine Matching Exhaust Systems to the Engine Running Computer Simulations Tuning Performance Engines Project; Preparing a Vintage Performance Engine Studying Sport Compact Engines Summary Review Questions 18 ENGINE INSTALLATION AND BREAK-IN Removing and Installing the Engine Inspecting and Servicing the Cooling System Preparing for Emissions Testing Making a Final Inspection Starting and Breaking-In the Engine Following Up on the Installation Summary Review Questions APPENDIX Q.EFERENCE TABLES Torque Recommendations, English Torque Recommendations, Metric Pipe Plug Torque Recommendatons Torque Conversions Decimal Equivalents for Drills Tap Drill Sizes, English Tap Drill Sizes, Metric Helicoil Tap Drill Sizes, English and Metric English-Metric Conversions Metric-English Conversions Conversion Factors KEY TO REVIEW QUESTIONS 17-3 17-7 17-11 17-14 17-16 17-16 17-17 17-18 17-24 17-27 17-29 17-31 17-34 17-35 17-36 17-47 17-51 17-52 18-1 18-3 18-5 18-8 18-8 18-9 18-9 18-10 A-1 A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 K-1