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Engine Test Equipment
Air and Water Pressure Tests

Engineman 2 - Intermediate engine mechanics training manual
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CHAPTER 3 INTERNAL COMBUSTION ENGINES This chapter is designed to help you understand the maintenance  and  repair  of  internal  combustion  engines. You  as  an  EN2  should  be  able  to  describe  the  basic procedures used to test and repair diesel engines. Also, you should be able to identify the procedures used to troubleshoot diesel and gasoline engines. This chapter will  cover  the  general  procedures  used  to  repair  and overhaul   gasoline   engines;   the   procedures   used   to inspect, test, and repair jacking gear; and the procedures used to troubleshoot and repair fuel and oil purifiers. To   help   ensure   that   an   engine   will   operate efficiently, you must follow its preventive maintenance schedule.  By  following  the  preventive  maintenance schedule, you will reduce engine casualties and help the engine  achieve  its  normal  number  of  operating  hours between overhaul periods. When you must finally perform an engine repair or overhaul, take the following precautions: l  Plan  the  work  in  definite  steps,  so  you  can perform  it  smoothly. l  Have  the  necessary  tools  and  parts  on  hand before you begin a repair or overhaul. l  Have  the  necessary  forms  ready  to  record  the clearances,  dimensions,  and  other  vital  measurement readings that must be kept as part of the engine’s history. l  Always  check  precision  measuring  instruments before you use them; then recheck your readings. The first reading may not be correct. l  Keep  the  work  area  clean.  Do  not  allow  oil  to accumulate on the deck or on the tools. Place the tools or parts neatly away from the immediate area. The   test,   maintenance,   and   repair   procedures presented  in  this  chapter  are  general  in  nature.  The specific procedures vary with different engines. Before you  begin  a  maintenance  or  repair  procedure,  consult the  manufacturer’s  technical  manual  or  the  equipment’s preventive  maintenance  schedules.  They  are  valuable sources   of   information   on   tests,   maintenance,   and repairs. INSPECTING AND TESTING THE ENGINE FRAME OR BLOCK Before you begin an inspection or test, make sure the outside of the engine is cleaned thoroughly. This will help you spot cracks, leaks, and other problems more easily than if the engine is dirty. By cleaning the engine, you will also help prevent dirt and other contaminants from entering and damaging parts and accessories of the engine. Some of the inspections and tests you may perform are  listed  in  the  following  sections. VISUAL INSPECTIONS Inspect the top surface of the cylinder block, the top and  bottom  crankcase  flanges,  and  the  oil  pan  for warpage. You can use a straightedge, a feeler gauge, and a  good  light.  Figure  3-1  illustrates  how  to  use  a straightedge and a feeler gauge to check the top surface of the cylinder block Compare your measurements to the  manufacturer’s  specifications  to  determine  if  the surface is warped. Visually   inspect   the   cylinder   block   for   cracks, breaks, or other damage. MEASUREMENTS Visually   inspect   the   engine   block’s   bolts   to determine if they are bent, broken, or worn. Figure 3-1.—Checking the top surface of a typical cylinder block. 3-1







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