201C - Engine Block & Cylinder Liner Service

Question 1

Cast iron cylinder blocks can be placed in a high temperature oven for cleaning. What temperature should it be baked at?

Answer 1

Cast iron:
500F - 700F for 5-6 hours

Aluminum:
400F for 2 hours

201C pg. 5

Question 2

What four methods can be used to check for cracks in a cylinder block?

Answer 2

• Dye check
• Magnetic Particle
• Magnaflux
• Pressure testing

201C pg. 7

Question 3

How is a cylinder block pressure tested for cracks?

Answer 3

20-40 psi
200F (93C)
15 - 20 minutes

Plug ports and use dummy injectors

201C pg. 8

Question 4

How is a cylinder block deck surface checked for flatness?

Answer 4

Straight edge and feeler blades
Minimum of 3 measurements must be taken.

Not to exceed 0.004”

201C pg. 10

Question 5

What are main bearing bores measured for?

Answer 5

• Max diameter
• Out of round
• Taper

Three measurements taken on either side of the bore, staying off the parting line during measurements.

Caps must be torqued to spec.

201C pg. 13

Question 6

How should a cylinder block be stored?

Answer 6

• Light coating of oil
• Main bearing caps torqued to 1/2 spec.
• Wrap in plastic
• Store in clean, dry location

201C pg. 16

Question 7

Where will the majority of cylinder wear occur?

Answer 7

90 degrees to the crankshaft centreline at the top of piston ring travel.

201C pg. 22

Question 8

On a clockwise rotating engine, what sides of the cylinder will be the major and minor thrust sides?

Answer 8

Major Thrust Side - Right hand side
Minor Thrust Side - Left hand side
(As viewed from the rear of engine)

201C pg. 22

Question 9

What is the purpose of a ridge reamer?

Answer 9

To remove the ridge at the top of ring travel created by wear.

Once ridge is removed, cylinders can be removed without damaging piston rings.

201C pg. 23

Question 10

When machining cylinder bores, how is the necessary oversized dimension determined?

Answer 10

Double the taper wear and use the next largest piston size available.

201C pg. 26

Question 11

What would be used to remove light scoring and small amounts of taper from a cylinder that is still within manufacture specifications?

Answer 11

Rigid hone

201C pg. 27

Question 12

What is cylinder crosshatch?
What angles should it be at?

Answer 12

Angled pattern of microscopic grooves in the cylinder wall that retains oil for lubricating piston rings.

Angle can vary from 40-60 degrees

201C pg. 28

Question 13

What tool would be used to de-glaze a cylinder wall?

Answer 13

Flexible hone / ball deglazer

201C pg. 28

Question 14

After honing or deglazing, how should the cylinder bores be cleaned?

Answer 14

Wash with hot water, detergent, stiff bristle brush.

Do not use solvents.

201C pg. 29

Question 15

Liner flange thicknesses should not vary by more than:

Answer 15

0.001”
Measured in 4 places, 90 degrees apart

201C pg. 36

Question 16

Counterbore measurements should not vary by more than:

Answer 16

0.001”
Measured with a sled gauge at 4 places, 90 degrees apart.

201C pg. 37

Question 17

How can liner height be adjusted?

Answer 17

By machining down the counterbore or adding shims in the counterbore.

201C pg. 38

Question 18

Installed liner heights are generally not permitted to vary by more than _______ from liner to liner.

Answer 18

0.002” - 0.003”

201C pg. 41

Question 19

Cast iron cylinder blocks can be placed in a high temperature oven for cleaning. What temperature should it be baked at?

Answer 19

Cast iron:
500F - 700F for 5-6 hours

Aluminum:
400F for 2 hours

201C pg. 5