Chapter 08: Introduction

After studying this chapter, you should be able to:

LO 8-1 Identify and describe the purpose and basic function of cylinder blocks and identify factors influencing current block design features and operation.

LO 8-2 Identify major cylinder block components and basic cylinder arrangements.

LO 8-3 Identify and describe the construction techniques and composition of cylinder blocks and outline the advantages and disadvantages of each design.

LO 8-4 Explain the purpose and methods used to increase the rigidity and strength of a diesel engine cylinder block.

LO 8-5 Identify and describe the configuration and construction of common cylinder block cylinder arrangements.

LO 8-6 Identify and outline the machining process to prepare the finish of a cylinder wall.

LO 8-7 Describe and outline the purpose and methods used to balance the weight of reciprocating cylinder components.

LO 8-8 Identify causes of bending and torsional stress of crankshafts and describe the methods used to minimize crankshaft mechanical stress.

LO 8-9 Explain the purpose, function, and construction of lubrication circuits for the crankshaft.

LO 8-10 Identify and describe the types of crankshaft vibration.

LO 8-11 Identify and describe the purpose, function, and types of diesel engine flywheels.

LO 8-12 Identify and describe the purpose, types, composition, and failures of plain split insert bearings.

LO 8-13 Outline the scope of cylinder block service and describe common service operations.

The fleet operation where you work is starting a program to inspect, replace, or rebuild all engines in-house rather than subcontract the work to an independent engine repair facility. The vehicles are part of a mixed-use operation; one-third of the trucks are heavy-duty (HD) on-highway tractors, one-third are medium-duty (MD) pickups and delivery vehicles, and one-third are vocational vehicles, such as flatbed delivery trucks and beverage haulers. You are tasked with preparing inspection and rebuild-reuse guidelines for the fleet’s engines. Using your guidelines, technicians will perform inspection procedures to determine whether the engines require overhaul or replacement and which components will be replaced if an engine is rebuilt. As you set out to prepare the guidelines, consider the following:

1. What type of engine blocks do you expect to encounter in each of the categories of vehicle use? Explain your answer.
2. Outline the inspection and overhaul procedures you can expect to perform for each category of engines encountered in the fleet.
3. Outline the service procedures you expect all the engines to undergo during overhaul and rebuild.