In-Frame Engine Overhaul

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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?

Both engine oil and Lubriplate 105 Signup and view all the answers

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

Clean the cap and bolts Signup and view all the answers

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

To select the correct replacement bearing Signup and view all the answers

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

Affected seating and heat transfer Signup and view all the answers

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

To push the tang end of the bearing Signup and view all the answers

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

Because of their higher load-bearing capacity Signup and view all the answers

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

To indicate their respective positions 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?

To ensure proper bearing installation Signup and view all the answers

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

To lift the crankshaft into position Signup and view all the answers

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

To ensure proper torque values Signup and view all the answers

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

To reduce friction Signup and view all the answers

What is the consequence of not checking bearing clearance?

Premature bearing failure Signup and view all the answers

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

To follow specific installation methods Signup and view all the answers

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

To reduce the chance of cylinder block distortion during the torquing process 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?

To ensure an even clamping force on each fastener Signup and view all the answers

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

It provides a more accurate method of ensuring the correct clamping force Signup and view all the answers

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

To detect any signs of binding or interference Signup and view all the answers

What is the consequence of insufficient bearing clearance?

Bearing seizure Signup and view all the answers

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

To determine the bearing clearance Signup and view all the answers

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

To determine the bearing clearance 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?

Loosen and carefully remove the bearing caps Signup and view all the answers

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

Damaging the bearing overlay Signup and view all the answers

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

To verify that the bearing clearance is within the recommended range Signup and view all the answers

What is the primary function of the crankshaft thrust bearings?

To control the endwise movement of the crankshaft Signup and view all the answers

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

Damaged thrust bearings and crankshaft thrust surfaces Signup and view all the answers

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

To measure the end play of the crankshaft Signup and view all the answers

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

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 Signup and view all the answers

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

To ensure proper sealing of gaskets Signup and view all the answers

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

To inspect the machined surfaces and seal bores Signup and view all the answers

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

Contact between the crankshaft and the webs of the cylinder block Signup and view all the answers

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

To measure the total amount of gauge deflection Signup and view all the answers

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

To ensure proper sealing of gaskets Signup and view all the answers

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

To measure the clearance between the thrust bearing and the thrust face 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?

To establish a reference point for subsequent readings Signup and view all the answers

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

Push the seal lip onto the crankshaft without rolling or damaging it 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?

To ensure the seal is installed in the correct direction Signup and view all the answers

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

The seal will leak prematurely Signup and view all the answers

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

To ensure the seal is installed to the correct depth Signup and view all the answers

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

The mounting surfaces for burrs and foreign material Signup and view all the answers

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

In a sequence according to the manufacturer's specifications Signup and view all the answers

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

To prevent the crankshaft from rotating during installation Signup and view all the answers

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

The runout of the vibration damper and flywheel 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?

To determine the serviceability of the flywheel housing Signup and view all the answers

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

Directing it away from the body Signup and view all the answers

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

Follow recommended first aid procedures Signup and view all the answers

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

To avoid inhaling fumes Signup and view all the answers

What should you do with components and parts after cleaning?

Store them in an orderly fashion Signup and view all the answers

Why is it important to inspect and measure crankshafts carefully?

To determine their serviceability Signup and view all the answers

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

Wearing personal protective equipment Signup and view all the answers

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

The oil plugs Signup and view all the answers

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

Fluorescent magnetic particle (Magnaflux) Signup and view all the answers

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

All of the above Signup and view all the answers

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

It should be coated with light preservative oil and wrapped in plastic Signup and view all the answers

What should be inspected for damaged threads on the crankshaft?

The threaded holes in the nose and the flange Signup and view all the answers

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

To check for grooves Signup and view all the answers

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

A gallery brush and solvent Signup and view all the answers

What should be done to the crankshaft after washing?

It should be blown dry with compressed air Signup and view all the answers

What should be inspected for cracks on the crankshaft?

The critically loaded areas Signup and view all the answers

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

A chisel Signup and view all the answers

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

All journals Signup and view all the answers

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

To identify the correct bearing size and type Signup and view all the answers

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

To install an oversized bearing Signup and view all the answers

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

Bearing failure Signup and view all the answers

What is the primary focus of inspecting crankshaft journals?

To measure the wear, out of round and taper Signup and view all the answers

What is the purpose of inspecting the crankshaft gear teeth?

To identify signs of wear and breakage Signup and view all the answers

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

To perform crack detection Signup and view all the answers

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

To measure the distance between the thrust surfaces Signup and view all the answers

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

To identify signs of wear and burrs Signup and view all the answers

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

It should be rechecked for cracks Signup and view all the answers

What is one way to check crankshaft straightness?

Mounting a dial indicator securely to the bench Signup and view all the answers

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

Bearing failure and premature engine wear Signup and view all the answers

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

To repair excessively worn or damaged journals 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?

To prevent incorrect measurements Signup and view all the answers

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

To verify the undersize dimension of the journals Signup and view all the answers

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

To calculate bearing clearance Signup and view all the answers

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

The smallest dimension with standard specifications Signup and view all the answers

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

To prevent journal damage Signup and view all the answers

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

To repair worn-out journals Signup and view all the answers

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

The amount of material removed from the journals Signup and view all the answers