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7 -CLEANED ALL THE ENGINE PART USING PROPER TYPE OF SOLVENT Part cylinder • • piston valves • • • • • • • gears • • Sheet metal parts and intake manifold • Solvent remove all the oil and loose material with a mild alkaline cleaner by spraying or brushing if stubborn deposit of carbon remain on the cylinder heads, the areas affected may be vapor blasted. blast the piston head with soft grit or by the vapor grit method apply crocus cloth moistened in mineral spirit, and polish the stem with dry crocus cloth degrease these parts by brushing on mineral spirit solvent. degrease these parts with mineral spirit solvent degrease these parts by brushing or spraying with mineral spirit solvent the oil passages must be pressureflushed with mineral spirit solvent and inspected with the aid of a flashlight the casting are immersed in an alkaline bath immersion in a caustic stripping bath when cold solvent are not effective spray or brush with mineral spirit solvent using a brass wire brush clean this parts by spraying or brushing with mineral spirit solvent, or use a cold emulsion type cleaner and flush with water to rinse spray or dip them in clean engine oil, or for longer storage, in corrosionpreventive oil mixture. remove with a hard Arkansas stone. cleaned with a suitable hydrocarbon solvent such as Naptha, Methyl Ethyl Ketone (Mek) or Trichloroethylene (TCE) cleaned the casting tapped hole with solvent and blow with compressed air.
Rocker shafts Pushrods, valve rockers and small steel parts. Camshaft and crankshaft crankcase
• casting • •
blow off all dust with dry compressed air and make sure that no grit has lodged in crevices. or powder is needed for cleaning engine parts. then air dried with dry compressed air No polishing compound. abrasive paste. After any blasting process. sandpaper. Such compound. recess and holes to prevent the formation of a foaming emulsion in the engine lubricating oil after reassembly. abrasive cloth . After removed soaked parts from inhibit. Scraping and abrasion with wire brushes. and buffing wheels are dangerous method to use on soft metal like aluminum. removed all traces of the alkaline by spraying the parts with a jet of steam or brush vigorously with a mineral spirit solvent. mild alkaline bath or hot soapy water. may become impregnated in the pores of the metal and causes oil foaming when the engine is returned to service .8 SAFETY PRECAUTION MUST BE TAKEN WHEN USING SPECIAL CLEANING EQUIPMENT • • • • • • All alkaline residue must be removed from crevices. Part may also be cleaned with hot soapy water. Extreme care must be exercised if any water-mixed degreased solution containing caustic compound or soap are used.WORK NO. in addition of being potentially dangerous to aluminum and magnesium. recess and holes.
The parts should be in groups whether it is serviceable. burred areas. pitted or otherwise damage valve seat. Cylinder head piston valve crankcase Push rod Ball bearing gears . pitting. scoring. Threaded parts should be inspected for nicks and damage to screw threads. Structural inspection • Visual inspection. Distortion. loose or damage spark plug heli coil insert. pitting or other damage Inspect all surface of the shaft for crack and check the bearing surface with particular care for scoring.WORK NO. corrosion. It is used on parts without critical dimensions. It must be conducted on all ferrous parts with correct methods and data in the table before dimensional inspection. scored. 1. loose or damage studs. Crankshaft should be demagnetize and remagnetize longitudinally for further inspection. galling. deep scratches visible cracks. repairable or discarded. Studs should be inspect for bending. loose cracked or scored valve guides and nicked. nicks and crack around the bearing support web and checked Examined for wear or looseness of ball end Examined visually and feel for roughness. The Magnaflow method is recommended and employs magnetic particles coated with a fluorescent organic material and can be illuminated with black light.9A POST CLEANING INSPECTION. parts camshaft crankshaft Visual inspection Inspect for crack. running parts by using at least a 10x magnifying glass and under good light for damage such as nicks. looseness or partial removal. flaking or pitting of races and for scoring on the outside of the races Examined for evidence of pitting and excessive gears • Magnetic particle inspection. pitting and other damage Examined for loose. corrosion. flat spots. galling. damage due to burning or corrosion Checked for burrs. dents. scored or denting pads Inspected for excessive pitting . small parts. cavaties or surface distortion Checked for physical damage.
using the loads and deflector as given in the manual The crankshaft is placed on the vee block. Dial indicator and surface plate were used to measure the run out at the center main bearing The crankshaft is placed on the vee block. total run out must not exceed 0. Rod must be straight within 0.WORK NO 9B: CARRY OUT DIMENSIONAL INSPECTION Parts Cylinder heads Dimensional inspection Checked for ID of each intake valve gide with flat rejection gage • Check the ID of the rocker shaft bushing in the cylinder head using that plug rejection gage • Check the diameter and out of round of the guide bore by checking with the gage at a minimum of 2 position 90 degree apart Check for the following measurement • Clearance between piston skirt and cylinder • Maximum taper of cylinder walls • Maximum out of roundness • Bore diameter Check for side clearance between piston ring and piston by using a feeler gage and straight edge Check OD of piston against ID of the hole in piston Check the ID of the rocker bushing with several different position with a flat plus rejection gage It was checked for straightness. Dial indicator and surface plate were used to measure the run out at the center main bearing Checked condition of bore in large end for seating of the bearing inserts and small end of bushing with connecting rod bushing Cylinder barrel piston Piston pin Rocker valve Push rods valve Valve spring crankshaft camshaft Connecting rod .0015 Check the condition of all valve spring on a suitable spring tester.010 Check run out of valve face.
plug gage RECIPROCATING OVERHAUL ASSIGMENT NAME : MOHD NORMUSTAKIM BIN ZULKIFLI CLASS : 4 FALCON ID NO : 531321040157 DUE DATE : 3RD AUGUST 2005 .