In-Frame Engine Overhaul

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Questions and Answers

What is the primary reason for performing a roll-in during an in-frame overhaul?

  • To replace the cylinder heads and pistons
  • To replace the main bearings (correct)
  • To remove the crankshaft from the cylinder block
  • To service the liners and connecting rods

In what order should the main cap and bearing removal pin be removed during the removal procedure?

  • Remove the bearing shell, then the main cap and bearing removal pin
  • Remove both simultaneously
  • Remove the main cap, then the bearing removal pin (correct)
  • Remove the bearing removal pin, then the main cap

What is the purpose of rotating the crankshaft during the removal procedure?

  • To clean and inspect the shaft
  • To provide access to the journal oil hole (correct)
  • To remove the bearing shell
  • To determine the size of the bearing

What is used to lubricate the face of the upper bearing shell during the replacement procedure?

<p>Both engine oil and Lubriplate 105 (C)</p> Signup and view all the answers

What is the next step after removing the bearing shell from the cap?

<p>Clean the cap and bolts (D)</p> Signup and view all the answers

What is the purpose of determining the size of the bearing during the replacement procedure?

<p>To select the correct replacement bearing (A)</p> Signup and view all the answers

What is the consequence of lubricating the back of the bearing?

<p>Affected seating and heat transfer (D)</p> Signup and view all the answers

What is the purpose of installing a bearing installation/removal pin in the oil hole of the journal?

<p>To push the tang end of the bearing (B)</p> Signup and view all the answers

Why are the front and rear main bearings replaced after the other main caps have been reinstalled?

<p>Because of their higher load-bearing capacity (C)</p> Signup and view all the answers

What is the purpose of marking the upper and lower bearing shells?

<p>To indicate their respective positions (C)</p> Signup and view all the answers

Why is it essential to ensure that the oil holes and tangs on the bearings align with the cylinder block?

<p>To ensure proper bearing installation (B)</p> Signup and view all the answers

What is the purpose of wrapping a nylon sling around the crankshaft journals?

<p>To lift the crankshaft into position (C)</p> Signup and view all the answers

Why is it important to follow the manufacturer's torque sequence for main cap bolts?

<p>To ensure proper torque values (C)</p> Signup and view all the answers

What is the purpose of lubricating the face of the upper bearing shell?

<p>To reduce friction (D)</p> Signup and view all the answers

What is the consequence of not checking bearing clearance?

<p>Premature bearing failure (A)</p> Signup and view all the answers

Why is it important to consult the manufacturer's service information during the bearing installation process?

<p>To follow specific installation methods (D)</p> Signup and view all the answers

What is the purpose of torquing the fasteners in multiple steps?

<p>To reduce the chance of cylinder block distortion during the torquing process (A)</p> Signup and view all the answers

What is the purpose of backing off the fasteners part of a turn after reaching the final torque value?

<p>To ensure an even clamping force on each fastener (D)</p> Signup and view all the answers

What is the advantage of the torque and turn method over torquing to a final value?

<p>It provides a more accurate method of ensuring the correct clamping force (B)</p> Signup and view all the answers

What is the purpose of checking the crankshaft for free rotation after torquing?

<p>To detect any signs of binding or interference (C)</p> Signup and view all the answers

What is the consequence of insufficient bearing clearance?

<p>Bearing seizure (D)</p> Signup and view all the answers

What is the purpose of using a telescoping gauge and an outside micrometer to measure bearing clearance?

<p>To determine the bearing clearance (A)</p> Signup and view all the answers

What is the purpose of using Plastigage™ to check bearing clearance?

<p>To determine the bearing clearance (B)</p> Signup and view all the answers

What should be done to the Plastigage™ strip after installing the main caps and torquing according to manufacturer’s specifications?

<p>Loosen and carefully remove the bearing caps (C)</p> Signup and view all the answers

What should be avoided when measuring the inside diameter of the assembled bearings?

<p>Damaging the bearing overlay (B)</p> Signup and view all the answers

What is the purpose of comparing the measured bearing clearance with the manufacturer’s specifications?

<p>To verify that the bearing clearance is within the recommended range (C)</p> Signup and view all the answers

What is the primary function of the crankshaft thrust bearings?

<p>To control the endwise movement of the crankshaft (C)</p> Signup and view all the answers

What is the consequence of insufficient end play in a crankshaft?

<p>Damaged thrust bearings and crankshaft thrust surfaces (D)</p> Signup and view all the answers

What is the purpose of mounting a dial indicator securely to the cylinder block?

<p>To measure the end play of the crankshaft (C)</p> Signup and view all the answers

What is the correct procedure to correct insufficient end play due to misaligned thrust surfaces?

<p>Loosen the thrust bearing main cap bolts one turn, push the crankshaft to the front and then to the rear, and retorque the main cap bolts (A)</p> Signup and view all the answers

Why is it important to check the alignment of gaskets and passageways during front housing installation?

<p>To ensure proper sealing of gaskets (C)</p> Signup and view all the answers

What is the purpose of removing the seals from the front gear cover and flywheel housing?

<p>To inspect the machined surfaces and seal bores (D)</p> Signup and view all the answers

What is the consequence of excessive end play in a crankshaft?

<p>Contact between the crankshaft and the webs of the cylinder block (A)</p> Signup and view all the answers

What is the purpose of using a dial indicator to measure crankshaft end play?

<p>To measure the total amount of gauge deflection (A)</p> Signup and view all the answers

What is the purpose of checking the alignment of the front gear cover after installation?

<p>To ensure proper sealing of gaskets (A)</p> Signup and view all the answers

Why is it important to use feeler gauges to measure crankshaft end play?

<p>To measure the clearance between the thrust bearing and the thrust face (C)</p> Signup and view all the answers

What is the purpose of zeroing the indicator at the 12 o'clock position when checking flywheel housing concentricity and alignment?

<p>To establish a reference point for subsequent readings (B)</p> Signup and view all the answers

What is the correct way to handle the seal lip when installing crankshaft oil seals?

<p>Push the seal lip onto the crankshaft without rolling or damaging it (C)</p> Signup and view all the answers

What is the purpose of using a Teflon lip directional seal assembly for the front and rear crankshaft oil seals?

<p>To ensure the seal is installed in the correct direction (C)</p> Signup and view all the answers

What is the consequence of removing the wear sleeve and handling or lubricating the seal lip during installation?

<p>The seal will leak prematurely (B)</p> Signup and view all the answers

What is the purpose of using special tooling to install the seal assembly?

<p>To ensure the seal is installed to the correct depth (B)</p> Signup and view all the answers

What should be checked on the vibration damper, flywheel, and crankshaft before installation?

<p>The mounting surfaces for burrs and foreign material (C)</p> Signup and view all the answers

In what sequence should the retaining bolts be torqued during the installation of the vibration damper and flywheel?

<p>In a sequence according to the manufacturer's specifications (B)</p> Signup and view all the answers

Why is it important to block the crankshaft during the installation of the vibration damper and flywheel?

<p>To prevent the crankshaft from rotating during installation (C)</p> Signup and view all the answers

What should be checked after installing the vibration damper and flywheel?

<p>The runout of the vibration damper and flywheel (A)</p> Signup and view all the answers

What is the purpose of comparing the indicator readings with the manufacturer's specifications during the checking of bore concentricity and flywheel housing alignment?

<p>To determine the serviceability of the flywheel housing (A)</p> Signup and view all the answers

What is the primary consideration when using compressed air for cleaning a crankshaft?

<p>Directing it away from the body (C)</p> Signup and view all the answers

What should you do if you come into contact with corrosive chemicals during crankshaft cleaning?

<p>Follow recommended first aid procedures (A)</p> Signup and view all the answers

Why is it important to work in a well-ventilated area when using chemicals and solvents?

<p>To avoid inhaling fumes (A)</p> Signup and view all the answers

What should you do with components and parts after cleaning?

<p>Store them in an orderly fashion (D)</p> Signup and view all the answers

Why is it important to inspect and measure crankshafts carefully?

<p>To determine their serviceability (A)</p> Signup and view all the answers

What is a key aspect of ensuring a safe working environment?

<p>Wearing personal protective equipment (D)</p> Signup and view all the answers

What should be removed for cleaning, especially if the crankshaft has been ground or polished?

<p>The oil plugs (C)</p> Signup and view all the answers

What method is used to detect cracks in a crankshaft, and is considered the most accurate?

<p>Fluorescent magnetic particle (Magnaflux) (A)</p> Signup and view all the answers

What should be inspected on the crankshaft for scoring and ridging?

<p>All of the above (D)</p> Signup and view all the answers

What should be done to the crankshaft if it is not being installed immediately after inspection?

<p>It should be coated with light preservative oil and wrapped in plastic (B)</p> Signup and view all the answers

What should be inspected for damaged threads on the crankshaft?

<p>The threaded holes in the nose and the flange (A)</p> Signup and view all the answers

What is the purpose of inspecting the seal surface area on the crankshaft?

<p>To check for grooves (B)</p> Signup and view all the answers

What should be used to clean the oil passages on the crankshaft?

<p>A gallery brush and solvent (C)</p> Signup and view all the answers

What should be done to the crankshaft after washing?

<p>It should be blown dry with compressed air (A)</p> Signup and view all the answers

What should be inspected for cracks on the crankshaft?

<p>The critically loaded areas (C)</p> Signup and view all the answers

What should be used to remove a wear sleeve from a crankshaft?

<p>A chisel (B)</p> Signup and view all the answers

What must be ground to the same dimension on a reground crankshaft?

<p>All journals (D)</p> Signup and view all the answers

Why is it necessary to check the engine tag or engine components for specific information?

<p>To identify the correct bearing size and type (C)</p> Signup and view all the answers

What is the purpose of reboring the bearing bore to an oversize?

<p>To install an oversized bearing (C)</p> Signup and view all the answers

What is the consequence of not matching the undersized bearing with the reground crankshaft?

<p>Bearing failure (C)</p> Signup and view all the answers

What is the primary focus of inspecting crankshaft journals?

<p>To measure the wear, out of round and taper (A)</p> Signup and view all the answers

What is the purpose of inspecting the crankshaft gear teeth?

<p>To identify signs of wear and breakage (B)</p> Signup and view all the answers

Why is it necessary to remove the gear when performing certain crankshaft service procedures?

<p>To perform crack detection (A)</p> Signup and view all the answers

What is the purpose of measuring the thrust surfaces of a crankshaft?

<p>To measure the distance between the thrust surfaces (D)</p> Signup and view all the answers

What is the purpose of inspecting the nose of the crankshaft and the gear mounting surface?

<p>To identify signs of wear and burrs (A)</p> Signup and view all the answers

What should be done to a crankshaft that has been straightened?

<p>It should be rechecked for cracks (D)</p> Signup and view all the answers

What is one way to check crankshaft straightness?

<p>Mounting a dial indicator securely to the bench (B)</p> Signup and view all the answers

What is the consequence of using a crankshaft that has not been reground to the correct undersize?

<p>Bearing failure and premature engine wear (D)</p> Signup and view all the answers

What is the purpose of building up the crankshaft journal using hard chromium plating or welding?

<p>To repair excessively worn or damaged journals (A)</p> Signup and view all the answers

Why is it important to stay away from oil holes and the fillet radius when measuring the journal surface?

<p>To prevent incorrect measurements (D)</p> Signup and view all the answers

Why is it necessary to check the manufacturer's specifications when grinding the crankshaft journals?

<p>To verify the undersize dimension of the journals (B)</p> Signup and view all the answers

What is the purpose of recording journal measurements in a table?

<p>To calculate bearing clearance (D)</p> Signup and view all the answers

What should be compared to determine the amount of journal wear?

<p>The smallest dimension with standard specifications (D)</p> Signup and view all the answers

Why is it important to lubricate the V-blocks during crankshaft straightness checking?

<p>To prevent journal damage (A)</p> Signup and view all the answers

What is the purpose of regrounding journals to an undersize dimension?

<p>To repair worn-out journals (B)</p> Signup and view all the answers

What is stamped on the front counterweight of a reground crankshaft?

<p>The amount of material removed from the journals (C)</p> Signup and view all the answers

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