Cylinder Block and Liner Inspection and Overhaul

Comprehensive vocabulary flashcards covering cylinder block cleaning, crack detection, pressure testing, bore inspections, machining effects, and wet/dry liner service procedures.

Hot tank (caustic solution)

A cleaning method that should not be used to clean aluminum components.

Expansion and threaded plugs

Plugs that should be removed when cleaning a cylinder block for overhaul so that coolant and oil passages can be thoroughly flushed.

Body or skin contact precaution

A safety requirement stating that high pressure, steam, or water must not contact any part of your body or skin during cylinder block cleaning.

Dye check

A method of crack detection that can be used on all types of materials.

Magnetic particle (magnaflux) cleaning requirement

The requirement to clean components thoroughly to remove test materials before reusing components tested using this method.

Hot water block immersion

Immersing a cylinder block in hot water during pressure testing to allow expansion of the block to heated operating temperature.

Straight edge and feeler gauge

The tools used to check the machined surfaces of the cylinder block for flatness.

Helicoils or solid thread inserts

The repair inserts most commonly used to repair stripped threads in a cylinder block casting.

Main bearing bore misalignment effects

A condition that can cause both excessive bearing wear and a broken crankshaft.

Main bearing cap reversed installation

Installing main bearing caps backwards or in the wrong position on the cylinder block, which causes misalignment of the bearing bores.

Main bearing bore measurements

Measurements taken to inspect main bearing bores to determine out of round and misalignment.

Cylinder block deck resurfacing

Machining the cylinder block deck surface to correct for warpage, which decreases the distance between the crankshaft centreline and the block deck.

Top of ring travel, $90^\circ$ to crankshaft centreline

The location where the majority of cylinder wear occurs in an engine cylinder.

Bore taper doubling rule

The procedure where measured cylinder taper (such as $0.009''$) is doubled to select the correct oversize to rebore the cylinder block (yielding $0.020''$).

De-glazing hone

A honing tool used when reconditioning a cylinder bore to restore cylinder wall crosshatch.

Cylinder bore post-honing cleaning

Thoroughly cleaning cylinder bores after honing or de-glazing using hot water, detergent, and a stiff bristle brush.

Screw type liner puller precautions

Two necessary safety precautions: do not scuff the deck and be careful when pulling the liner up.

Vertical liner storage

Storing liners vertically to prevent distortion after removal from the cylinder block.

Wet liner counterbore visual inspection

A visual examination of wet liner counterbores for cracks, erosion, and signs of coolant leakage.

Liner cavitation

A defect characterized by pitting on the outer surface of a wet liner.

Installed liner height calculation

The calculation where flange thickness plus shim thickness minus counterbore depth equals installed height: $(0.441'' + 0.003'') - 0.439'' = 0.005''$.

Counterbore depth variation repair

The service procedure of machining the counterbores and using shims to restore liner height when measurements vary by $0.004''$.

Dry liner loose fit repair

The repair procedure of boring or honing the block for oversized liners when dry liners fit the block with excessive clearance.

Twisted wet liner seal rings

Seal rings that roll or twist during installation, causing distortion of the liner bore.

Wet liner seal ring lubrication timing

The practice of lubricating wet liner seal rings just before liner installation.