Small Gas Engines. Small Gas Engine Inspection, Measurement, and Cleaning. User s Guide

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1 Small Gas Engines Small Gas Engine Inspection, Measurement, and Cleaning User s Guide

2 Introduction This video explains the procedures used to properly inspect, clean, and service components before reassembling a small gas engine. If engine parts are not cleaned and serviced correctly, a small engine can self-destruct in a matter of seconds after the initial start-up. The program stresses the importance of detailed inspection and accurate measurement of part wear during an engine rebuild. It also demonstrates how to use the necessary instruments when measuring for such things as cylinder bore wear, piston wear, cylinder head warpage, and other critical part measurements. To successfully rebuild a small gas engine, you not only have to understand its construction and operating principles, you also must know the proper procedures used to clean, inspect, and service engine components. This program explains those procedures and supplies viewers with additional information needed to prepare an engine for reassembly. Student Objectives After viewing this video, you will be able to: Explain the safety rules to follow when preparing small engine parts for engine reassembly. List several of the measuring devices used during a small gas engine rebuild. Properly clean and inspect a small engine s cylinder block. Check for cylinder bore wear in a small engine s cylinder block. Describe how to deglaze a cylinder on a small gas engine. Inspect the four critical areas of a small engine s piston for damage or wear. Check the condition of a small engine s connecting rod. Describe how to check the condition of the oil pump on certain small gas engines. Inspect and measure a small engine s crankshaft for wear. Explain how to service a small engine s valve train. To The Instructor This video is organized into major sections or topics. Each section covers one major segment of the subject. Graphic breaks are given between each section so that you can stop the video for class discussion, to answer critical questions, to ask questions, or perform in-class demonstrations with actual components or parts. The program s format is arranged to be flexible. View it full-length, or use it as a supplement for lectures or demonstrations. It can also be used for self-paced individualized instruction. You can watch a portion of the program each day, or present the complete video, depending on your curriculum requirements. 2 The program is designed to simplify the complex. Concise wording and carefully selected graphics are used to provide maximum learning in minimum time. Close-up shots of components and service procedures are used to make every second of viewing instructional, as if each student were standing right behind you, watching over your shoulder while you were working or giving a demonstration. Our technical visual images are designed to match the audio so that every scene has maximum educational value. Computer animation is used to explain difficult principles or techniques. Students seem to enjoy the images that show how parts work, how they fit together, and how they vary in design. Copyright 1993 Meridian Education Corporation

3 Quiz Answer Key 1) b 4) c 7) a 10) b 13) b 2) a 5) a 8) b 11) c 14) c 3) c 6) d 9) d 12) b 15) b Use your own judgment to evaluate the technical terms, discussion topics, and short answers. Technical Terms Write definitions for the following terms. Use a textbook or review the video, if needed. cylinder block crankcase cover cylinder bore ring ridge combustion chamber cylinder head bearing bores connecting rod connecting rod big end connecting rod small end valve seats valve guides valve stem valve springs valve keepers valve retainers valve stem tip valve face interference angle cylinder deglazing rigid hone engine crankcase flex hone cylinder out-of-roundness cylinder taper cylinder head ports engine cooling fins cylinder bore wear dial bore gauge micrometer crankcase seals cylinder block bearings cylinder head gasket surface hole gauge outside micrometer knurled straightedge feeler gauge piston skirt piston boss piston head piston pin piston rings piston ring expander tool piston ring groove engine crankshaft crankshaft journals rocker arms push rods lifters valve seat angle valve grinding machine valve face angle valve grinding compound Discussion Topics Here are a few topics that might be used for a class discussion. 1. Why should you remove any dirt or grime from a small engine cylinder block before inspecting it for problems? 2. Describe how to measure cylinder bore wear in a small gas engine. 3. Why is it important to locate any worn bearings during a small engine rebuild? 4. Describe how to properly deglaze a small engine cylinder. 5. Explain the procedures used to clean a small engine cylinder head. 6. What should you do if you find any problems with a small engine s connecting rod? 7. What safety rules should be followed when using a wire wheel to remove carbon deposits from a small engine s valves? 3 8. Describe the basic procedures used to perform a valve job on a small gas engine.

4 Quiz Choose the most correct answer after reading the statement. 1. If a small engine s cylinder block has a ring ridge, the is probably badly worn. a. crankshaft b. cylinder c. camshaft d. head 2. If the valve are located in the block, you should inspect them closely for burning, physical damage, or wear. a. seats b. keepers c. springs d. retainers 3. If a bearing is machined as part of the crankcase, it is probably better to buy a new than to try to repair the bearing surface. a. bearing b. seal c. crankcase d. cylinder 4. Deglazing is sometimes recommended by the engine manufacturer for cast iron cylinders and aluminum cylinders that are used with rings. a. carbon b. magnesium c. chrome d. solid 5. A hone should be used to remove a small amount of taper from a small engine s cylinder. a. rigid b. carbon c. flex d. brush 6. A is normally used to remove any heavy carbon deposits inside the engine s combustion chamber. a. grinder b. driver c. cutter d. scraper 4 7. When cleaning a small engine s cylinder head, you should wipe away any debris from the cooling to prevent engine. a. fins, overheating b. ports, stalling c. vents, knocking d. none of the above

5 8. If a small engine s valve guides are worn beyond specs, they should be or. a. ground, honed b. knurled, replaced c. honed, replaced d. knurled, ground 9. Which of the following set of devices are used to measure cylinder head warpage? a. dial bore gauge, feeler gauge b. micrometer, dial bore gauge c. straightedge, hole gauge d. feeler gauge, straightedge 10. Piston diameter minus piston pin diameter equals piston pin clearance. a. rod b. bore c. skirt d. head 11. When inspecting the condition of a small engine s, always check the snout threads and journals for damage. a. camshaft b. lifters c. crankshaft d. governor 12. If a small engine s camshaft is replaced, you should also install new. a. valves b. lifters c. keepers d. retainers 13. When inspecting the condition of a small engine s rocker arms, it is important that you check where they contact the and the push rods. a. keepers b. valves c. retainers d. springs 14. A valve grinding machine uses a large grinding to remachine the valve. a. plate, head b. shaft, guide c. stone, face d. pad, guide Valve grinding can be used to check a valve job performed on a small gas engine. a. pads b. compound c. oil d. cutters

6 Short Answers Briefly answer the following questions in your own words. 1. What should you look for when inspecting a small engine s cylinder block for problems? 2. Why is it important to use caution when using a scraper to remove gasket material from a small engine s cylinder block and crankcase cover? 3. Describe the basic purpose of a flex hone. 4. Why is it essential to properly clean a small engine s cylinder after honing? 5. Describe how to check a small gas engine for valve guide wear. 6. Explain how to check a small engine s piston for wear. 7. How do you remove the rings from a small engine s piston? 8. What should be done if a small engine s valve stems are worn beyond specs? 9. How can a worn cam lobe affect the performance of a small gas engine? 10. What type of problems should you look for when inspecting a small engine s push rods for damage? 6

7 For information on other programs visit our website at Brunswick Pike, Lawrenceville, NJ Toll Free: 1 800/ Fax: 1 888/

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