Job Sheet 1 - Community College of Philadelphia
AT 181 - Block, Crank, and Pistons worksheet.
Names ________________________________________________________________ Date _______________________
Measuring Deck Warpage
Upon completion of this job sheet, you should be able to properly inspect and measure the engine block deck for warpage.
ASE Correlation
This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Visually inspect engine block for cracks, corrosion, passage condition, core and gallery plug holes, and surface warpage; determine necessary action.
Tools and Materials
Straightedge
Feeler gauge
Engine block
Procedure
Using the engine you have disassembled and the proper service manual, you will identify and perform the required steps to inspect and measure the engine block deck for warpage.
11. Specification for maximum warpage allowed. _______________________
12. Special tools required to perform this procedure?
13. Make sure the deck surface is clean. Task Completed □
14. Note any damage (nicks, scratches, etc.) to the deck surface.
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
15. Actual warpage measurement.
Left bank _________________ Right bank _____________
16. Based on your findings, what is your recommendation?
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Instructor’s Response __________________________________________________________
Inspecting and Measuring the Cylinder Walls
Upon completion of this job sheet, you should be able to properly inspect and measure the cylinder walls for wear.
ASE Correlation
This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Inspect and measure cylinder walls; remove cylinder wall ridges; hone and clean cylinder walls; determine need for further action.
Tools and Materials
Dial bore gauge
Engine block
Procedure
Using the block from the engine you have disassembled and the proper service manual, you will identify and perform the required steps to inspect and measure the cylinder walls for wear.
11. Do any of the cylinders have visible signs of wear or damage? □ Yes □ No
If YES, which one(s)?
__________________________________________________________________________
__________________________________________________________________________
12. Is the cross-cut pattern still visible on all cylinder walls? □ Yes □ No
If NO, on which ones is it no longer visible?
__________________________________________________________________________
__________________________________________________________________________
13. What is the specification for the bore? _____________________
14. At what location in the cylinder is the bore measurement to be taken?
__________________________________________________________________________
15. What is the specification for the maximum amount of taper? _________________
16. At what locations in the cylinder is the taper measured?
__________________________________________________________________________
17. What is the specification for the maximum amount of out-of-round? _________________
__________________________________________________________________________
18. At what location in the cylinder is out-of-round measured?
__________________________________________________________________________
19. Measure each cylinder at the locations required, and record your results.
Bore Taper Out-of-Round
Cylinder 1 _____ _____ ___________
Cylinder 2 _____ _____ ___________
Cylinder 3 _____ _____ ___________
Cylinder 4 _____ _____ ___________
Cylinder 5 _____ _____ ___________
Cylinder 6 _____ _____ ___________
10. Put an * (or more than one if necessary) in the chart above to indicate any readings that are out-of-specification.
Task Completed □
11. Have the cylinders been bored to an oversize? □ Yes □ No
If YES, what size? ___________________________________________________
12. Based on your readings, what is your recommendation?
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Instructor’s Response __________________________________________________________
Inspecting and Measuring Main Bearing Bore Alignment
Upon completion of this job sheet, you should be able to properly inspect and measure the main bore alignment.
ASE Correlation
This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Inspect and measure main bearing bores and cap alignment and fit.
Tools and Materials
Straightedge
Feeler gauge
Engine block
Procedure
Using the block from the engine you have disassembled and the proper service manual, you will identify and perform the required steps to inspect and measure the main bores for proper alignment.
11. Do any of the main bearings show signs of wear caused by bore misalignment?
□ Yes □ No
If YES, which one(s)?
__________________________________________________________________________
__________________________________________________________________________
12. Do any of the saddles or caps have visible signs of wear or damage?
□ Yes □ No
If YES, which one(s)?
__________________________________________________________________________
__________________________________________________________________________
13. What is the maximum amount of bore misalignment allowed? ______________________
14. Describe the method used to determine bore misalignment.
__________________________________________________________________________
__________________________________________________________________________
Inspecting and Measuring Main Bearing Bore Alignment (continued)
15. Actual amount of bore misalignment. ___________________________________________
16. Based on your findings, what is your recommendation?
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Instructor’s Response __________________________________________________________
Inspecting the Pistons and Connecting Rods
Upon completion of this job sheet you should be able to properly inspect pistons, connecting rods, and piston pins. You should also be able to remove a piston from a connecting rod.
ASE Correlation
This job sheet is related to ASE Engine Repair Test content area: Engine Block Assembly Diagnosis and Repair; tasks: Inspect and measure pistons and determine necessary action; Remove and replace piston pin.
This job sheet is also related to ASE General Engine Diagnosis; Removal and Reinstallation (R&R); tasks: Research applicable vehicle service information.
Tools and Materials
Micrometer
Vise
Press
Piston pin press tools
Procedure
Your instructor will provide you with a specific engine. Write down the information, and then perform the following tasks:
11. Line up the pistons and connecting rods in order on a clean bench.
Task Completed □
12. Visually inspect each connecting rod for damage, bend, cracks, nicks. Record results.
Piston number 1 ____________________________________________________________
Piston number 2 ____________________________________________________________
Piston number 3 ____________________________________________________________
Piston number 4 ____________________________________________________________
Piston number 5 ____________________________________________________________
Piston number 6 ____________________________________________________________
13. Remove the rod bearings and keep them in order for later inspection.
Task Completed □
4. Clean the big end bore; note any visible issues, and measure the diameter and for out-of-round. Record results:
Rod number 1 ______________________________________________________________
Rod number 2 ______________________________________________________________
Rod number 3 ______________________________________________________________
Rod number 4 ______________________________________________________________
Rod number 5 ______________________________________________________________
Rod number 6 ______________________________________________________________
5. Remove the piston rings using a ring expander and be careful not to scrape the sides of the pistons. Lay to the side for later inspection. Clean the ring grooves using a ring groove cleaner. Task Completed □
6. Visually inspect the piston ring grooves, ring lands, piston heads, and piston skirts for excessive scuffing. Record results:
Piston number 1 ____________________________________________________________
Piston number 2 ____________________________________________________________
Piston number 3 ____________________________________________________________
Piston number 4 ____________________________________________________________
Piston number 5 ____________________________________________________________
Piston number 6 ____________________________________________________________
7. Locate the manufacturer’s service information for where to measure piston diameter. Record that procedure:
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
8. Measure the piston diameter and compare it to specifications. Record results:
Piston number 1 diameter __________________ Within specification? □ Yes □ No
Piston number 2 diameter __________________ Within specification? □ Yes □ No
Piston number 3 diameter __________________ Within specification? □ Yes □ No
Piston number 4 diameter __________________ Within specification? □ Yes □ No
Piston number 5 diameter __________________ Within specification? □ Yes □ No
Piston number 6 diameter __________________ Within specification? □ Yes □ No
9. Hold one piston assembly and feel for free movement of the connecting rod. Place a shop rag around the connecting rod and place it in a vise. Push up and down on the piston to feel for even the slightest vertical movement. It should move sideways freely. Repeat for each piston and rod assembly. Note your results:
Piston number 1 ____________________________________________________________
Piston number 2 ____________________________________________________________
Piston number 3 ____________________________________________________________
Piston number 4 ____________________________________________________________
Piston number 5 ____________________________________________________________
Piston number 6 ____________________________________________________________
10. If any pistons felt loose on the rod and your shop has the proper press and piston pin adaptor, remove those pistons from the rod.
Does your shop have the proper equipment to remove the piston? □ Yes □ No
11. If your shop does not have the proper equipment, have your instructor check your work now.
12. If you have the equipment, note or mark the orientation of the piston on the rod. Set the piston and pin press adaptor on the vise. Be certain the piston and press rod are aligned properly. You must have safety glasses on. Press the pin from the piston and connecting rod. Repeat for as many piston assemblies as required. If the piston pins are full floating, simply remove the snap rings and push the pins out.
Did you successfully remove the pin(s)? □ Yes □ No
13. Set the piston and connecting rod aside. Visually inspect the piston pin for wear and measure its diameter. Record your results:
Pin number 1 visual condition and diameter: _____________________________________
Pin number 2 visual condition and diameter: _____________________________________
Pin number 3 visual condition and diameter: _____________________________________
Pin number 4 visual condition and diameter: _____________________________________
Pin number 5 visual condition and diameter: _____________________________________
Pin number 6 visual condition and diameter: _____________________________________
14. Compare the pins to specification. Which, if any, are worn? ________________________
__________________________________________________________________________
15. Inspect the connecting rod and piston bore for signs of wear. Measure the connecting rod bore using an inside micrometer or a dial bore gauge. Compare the bore to specifications. (On some piston assemblies, it will also be necessary to measure the bore in the piston; perform the work as specified in the service information.) Record results:
Bore number 1 diameter ______________________ Within specifications? □ Yes □ No
Bore number 2 diameter ______________________ Within specifications? □ Yes □ No
Bore number 3 diameter ______________________ Within specifications? □ Yes □ No
Bore number 4 diameter ______________________ Within specifications? □ Yes □ No
Bore number 5 diameter ______________________ Within specifications? □ Yes □ No
Bore number 6 diameter ______________________ Within specifications? □ Yes □ No
16. Describe any work necessary to repair improper piston to rod fit. Record results:
Piston number 1 ____________________________________________________________
Piston number 2 ____________________________________________________________
Piston number 3 ____________________________________________________________
Piston number 4 ____________________________________________________________
Piston number 5 ____________________________________________________________
Piston number 6 ____________________________________________________________
Instructor’s Response __________________________________________________________
Inspecting the Bearing Wear Patterns
Upon completion of this job sheet, you should be able to inspect main and connecting rod bearings and determine problems indicated by unusual wear patterns.
ASE Correlation
This job sheet is related to ASE Engine Repair Test content area: Engine Block Assembly Diagnosis and Repair; tasks: Inspect piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; inspect rod alignment and bearing bore condition.
Procedure
Your instructor will provide you with a specific engine. Write down the information, and then perform the following tasks:
11. Lay the main bearing halves out with main number 1 bottom half below main number 1 top half. Line up the rest in order in the same fashion. Describe the visual wear on the front and back of each bearing. Record results:
Bearing number 1 bottom ____________________________________________________
Bearing number 1 top________________________________________________________
Bearing number 2 bottom ____________________________________________________
Bearing number 2 top________________________________________________________
Bearing number 3 bottom ____________________________________________________
Bearing number 3 top________________________________________________________
Bearing number 4 bottom ____________________________________________________
Bearing number 4 top________________________________________________________
Bearing number 5 bottom ____________________________________________________
Bearing number 5 top________________________________________________________
Bearing number 6 bottom ____________________________________________________
Bearing number 6 top________________________________________________________
Bearing number 7 bottom ____________________________________________________
Bearing number 7 top________________________________________________________
2. Is the bearing wear uneven around the bearing halves? □ Yes □ No Does the pattern of bearing wear indicate the possibility of main bearing bore misalignment? □ Yes □ No
3. If main bearing bore misalignment is a possibility, check it now. Torque the main caps on in the proper sequence to the proper specification. Task Completed □
Look up the specification for the maximum allowable main bore misalignment. Record
results: ___________________________________________________________________
Lay a straightedge in the top and bottom of the bearing bores and try to fit a feeler gauge the size of the allowable misalignment under the straightedge in each cap.
Does the feeler gauge fit anywhere? □ Yes □ No
If the misalignment is too great, describe the procedure to fix the problem:
__________________________________________________________________________
4. Do your bearings show any concentrated wear on the sides, indicating that a bearing cap was misaligned? □ Yes □ No
5. Are your bearings smeared, indicating improper or inadequate lubrication, or dirt behind the bearing back? □ Yes □ No
6. Are any of your bearing backs scored or polished, indicating that they may have spun in their bore? □ Yes □ No
7. Do any of your connecting rod bearings indicate wear on the opposite sides of the upper and lower bearing, indicating a bent connecting rod? □ Yes □ No
8. Describe your overall assessment of the main and rod bearings in your engine and what corrective actions you will have to take before reassembling your engine.
Main bearing indications:
__________________________________________________________________________
__________________________________________________________________________
Rod bearing indications:
__________________________________________________________________________
__________________________________________________________________________
Corrective actions:
__________________________________________________________________________
__________________________________________________________________________
Instructor’s Response __________________________________________________________
Installing the Piston Rings
Upon completion of this job sheet, you should be able to properly install piston rings.
ASE Correlation
This job sheet is related to ASE Engine Repair Test content area: Engine Block Assembly Diagnosis and Repair; tasks: Inspect, measure, and install piston rings.
This job sheet is also related to ASE General Engine Diagnosis; Removal and Reinstallation (R&R) tasks: Research applicable vehicle service information.
Tools and Materials
Ring expander
Feeler gauges
Procedure
Your instructor will provide you with a specific engine. Write down the information, and then perform the following tasks:
11. Locate the correct rings for your engine. Look up the correct installation of the ring gaps and draw a diagram showing it below:
Installing the Piston Rings (continued)
12. Look up the specification for ring side clearance and for ring end gap. Record results:
Ring side clearance specification: ______________________________________________
Ring end gap specification: ___________________________________________________
13. Place an oil ring in the cylinder where indicated by the service information or toward the bottom of ring travel and square it with a piston. Measure the end gap. Place the second ring in the cylinder and measure the end gap. Place the top ring in the cylinder and measure the end gap. Repeat for all cylinders. Record results:
Cyl. #1: oil gap _______________ Second gap _______________ Top gap _________________
Cyl. #2: oil gap _______________ Second gap _______________ Top gap _________________
Cyl. #3: oil gap _______________ Second gap _______________ Top gap _________________
Cyl. #4: oil gap _______________ Second gap _______________ Top gap _________________
Cyl. #5: oil gap _______________ Second gap _______________ Top gap _________________
Cyl. #6: oil gap _______________ Second gap _______________ Top gap _________________
14. Are any gaps too wide? □ Yes □ No What, if anything, will you do to correct this?
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Are any gaps too narrow? □ Yes □ No What, if anything, will you do to correct this?
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
15. Lubricate piston number 1. Install the oil ring, expander, and second oil ring by hand, being careful not to twist them excessively. Use a ring expander to properly install the second ring. Is there a top marking? □ Yes □ No
Use a ring expander to properly install the top ring. Is there a top marking? □ Yes □ No
Repeat for all pistons.
16. Measure ring side clearance for the oil, second, and top rings as specified. Repeat for each piston. Record results:
Piston #1 oil clearance __________ Second clearance ___________ Top clearance ___________
Piston #2 oil clearance __________ Second clearance ___________ Top clearance ___________
Piston #3 oil clearance __________ Second clearance ___________ Top clearance ___________
Piston #4 oil clearance __________ Second clearance ___________ Top clearance ___________
Piston #5 oil clearance __________ Second clearance ___________ Top clearance ___________
Piston #6 oil clearance __________ Second clearance ___________ Top clearance ___________
17. Space the gaps as instructed on each piston. Task Completed □
Instructor’s Response __________________________________________________________
Installing the Main Bearings and the Crankshaft
Upon completion of this job sheet, you should be able to install the main bearings and the crankshaft into the engine block properly.
ASE Correlation
This job sheet is related to the Engine Repair Test’s content area: Engine Block Diagnosis and Repair; tasks: Install main bearings and crankshaft; check bearing clearances and end play; re-place/retorque bolts according to manufacturer’s procedures.
Tools and Materials
Dial indicator
Plastigage
Torque wrench
Engine block
Procedure
Using the engine block and crankshaft from the engine you have disassembled and the proper service manual, you will identify and perform the required steps to install the main bearings and the crankshaft.
11. Replace the pilot bushing or bearing installed in the end of crankshaft (used with manual transmissions). Task Completed □
12. Make sure the proper main bearings are selected for the engine. Does this engine use
select bearings? □ Yes □ No
If YES, how are they identified?
__________________________________________________________________________
13. Clean the block saddles, caps, and bearings thoroughly. Task Completed □
14. Install all upper bearing inserts into the block. These inserts will have oil holes and grooves that must be properly aligned with the block. Make sure to install the thrust washer into the specified saddle. Which bore is the thrust bearing installed in?
__________________________________________________________________________
15. Install the lower bearing inserts into the caps. Task Completed □
16. Inspect the cap bolts for damage. Task Completed □
17. What is the specification for main bearing oil clearance?
__________________________________________________________________________
18. Is the specification for ACTUAL or TOTAL oil clearance? Task Completed □
19. What method of measuring oil clearance is recommended by the service manual?
__________________________________________________________________________
10. If using Plastigage, install the crankshaft into the saddles. When installing the crankshaft, lift it by the harmonic balancer journal and by bolts threaded into the rear flange. As the crankshaft is lowered into the bearings, keep it parallel to the bearings, and lower it straight down. If installed properly, the crankshaft will seat square and be supported by the bearings.
Task Completed □
11. Measure the oil clearance of each main bearing, and record your results below.
Bore Number Clearance
1 ____________
2 ____________
3 ____________
4 ____________
5 ____________
12. Place an * (or more than one, if necessary) in the previous chart to indicate any oil clearances that are out-of-specification. If any clearances are out-of-specification, what procedure can be used to correct them?
__________________________________________________________________________
__________________________________________________________________________
13. Correct any oil clearances to specifications as needed. Task Completed □
14. If the rear main seal is a two-piece lip seal, install the pieces into the block and rear cap. Which direction must the lip of the seal face?
__________________________________________________________________________
15. Lubricate the inside surfaces of the bearing inserts with a film of engine oil.
Task Completed □
16. Install the crankshaft, caps, and bolts. Apply anaerobic sealer between the rear cap and cylinder block (if needed). Task Completed □
17. Place the main bearing caps over the crankshaft journals, starting at the rear journal and working toward the front of the engine, making sure the correct cap is installed in the correct location and in the proper direction. Task Completed □
18. Register the main bearing caps by tightening the cap bolts by hand while rotating the crankshaft. Task Completed □
19. With the main bearing cap bolts fingertight, pry the crankshaft back and forth to align the thrust bearing. Task Completed □
20. Rotate the crankshaft. Does it rotate freely with no binding or restrictions?
□ Yes □ No
If NO, correct any problems before continuing.
21. What is the torque specification for the main bearing cap bolts?
__________________________________________________________________________
22. In the space below, draw the torque sequence for the main bearing cap bolts.
23. Torque the bolts of the first cap in sequence to the specified value. Task Completed □
24. Check crankshaft rotation by rotating it with a torque wrench. Note the amount of torque required to rotate the crankshaft during several revolutions.
__________________________________________________________________________
25. Torque the next cap in the sequence, and check the rotating torque of the
crankshaft again. Task Completed □
26. Continue to torque the cap bolts in sequence, making sure to check rotating torque after each cap is tightened. Record the turning torque of the crankshaft for the remaining caps below.
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
27. Were there any large increases in the torque required to rotate the crankshaft?
□ Yes □ No
If YES, stop and locate the cause of the problem.
28. With all cap bolts properly torqued, check the rotating torque of the crankshaft.
Specification _____________ Actual _________________
29. If the engine uses a one-piece lip seal, install it. Task Completed □
30. Check crankshaft end play.
Specification _____________ Actual _________________
Instructor’s Response __________________________________________________________
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