WORK NO.

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

Stud replacement

WORK NO.8 SAFETY PRECAUTION MUST BE TAKEN WHEN USING SPECIAL CLEANING EQUIPMENT All alkaline residue must be removed from crevices, recess and holes to prevent the formation of a foaming emulsion in the engine lubricating oil after reassembly. After any blasting process, blow off all dust with dry compressed air and make sure that no grit has lodged in crevices, recess and holes. Part may also be cleaned with hot soapy water, then air dried with dry compressed air No polishing compound, abrasive paste, or powder is needed for cleaning engine parts. Scraping and abrasion with wire brushes, sandpaper, abrasive cloth , and buffing wheels are dangerous method to use on soft metal like aluminum. After removed soaked parts from inhibit, mild alkaline bath or hot soapy water, removed all traces of the alkaline by spraying the parts with a jet of steam or brush vigorously with a mineral spirit solvent. Extreme care must be exercised if any water-mixed degreased solution containing caustic compound or soap are used. Such compound, in addition of being potentially dangerous to aluminum and magnesium, may become impregnated in the pores of the metal and causes oil foaming when the engine is returned to service

WORK NO.9A POST CLEANING INSPECTION. 1. Structural inspection Visual inspection. It is used on parts without critical dimensions, small parts, running parts by using at least a 10x magnifying glass and under good light for damage such as nicks, dents, deep scratches visible cracks. Distortion, burred areas, pitting. Studs should be inspect for bending, looseness or partial removal. Threaded parts should be inspected for nicks and damage to screw threads. The parts should be in groups whether it is serviceable, repairable or discarded. parts camshaft crankshaft Visual inspection Inspect for crack, scoring, galling, corrosion, pitting or other damage Inspect all surface of the shaft for crack and check the bearing surface with particular care for scoring, galling, corrosion, pitting and other damage Examined for loose, scored, pitted or otherwise damage valve seat, loose or damage studs, loose or damage spark plug heli coil insert, loose cracked or scored valve guides and nicked, scored or denting pads Inspected for excessive pitting , cavaties or surface distortion Checked for physical damage, damage due to burning or corrosion Checked for burrs, nicks and crack around the bearing support web and checked Examined for wear or looseness of ball end Examined visually and feel for roughness, flat spots, 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. It must be conducted on all ferrous parts with correct methods and data in the table before dimensional inspection. The Magnaflow method is recommended and employs magnetic particles coated with a fluorescent organic material and can be illuminated with black light. Crankshaft should be demagnetize and remagnetize longitudinally for further inspection.

Cylinder head

piston valve crankcase Push rod Ball bearing gears

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. Rod must be straight within 0.010 Check run out of valve face, total run out must not exceed 0.0015 Check the condition of all valve spring on a suitable spring tester, 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. 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

plug gage

RECIPROCATING OVERHAUL ASSIGMENT

NAME : MOHD NORMUSTAKIM BIN ZULKIFLI CLASS : 4 FALCON ID NO : 531321040157 DUE DATE : 3RD AUGUST 2005