Deck 15: Engine Removal, Disassembly, Cleaning,

Question 1

Before removing a truck diesel engine from a chassis, which of the following steps is recommended FIRST?

A) disconnect the battery
B) pressure wash the engine
C) drain the coolant
D) discharge the A/C refrigerant

Answer 1

pressure wash the engine

Question 2

Before removing an electronically managed engine which of the following should be downloaded and retained?

A) customer data programming
B) proprietary data programming
C) cruise control preferences
D) driver rewards programming

Answer 2

customer data programming

Question 3

What should you do to engine coolant after draining if it is to be reused?

A) store in an open container
B) mix it with distilled water
C) store in a sealed container
D) add an SCA charge to it

Answer 3

store in a sealed container

Question 4

On engines with a non-volatile RAM component, what should you do before disconnecting the batteries, prior to removing the engine?

A) nothing
B) check the OEM service literature
C) dump ECM cache
D) cycle the ignition key

Question 5

After you remove a turbocharger that will be returned to service, from an engine, which of the following should be done?

A) recore
B) separate compressor from turbine housing
C) cap all inlet and outlet ports
D) store upright

Question 6

When the rear engine mounts are located on the flywheel housing, which of following must be done before removing an engine from the chassis?

A) support engine oil pan
B) support radiator assembly
C) support charge air cooler
D) support the transmission

Question 7

Which of the following device(s) should be used in conjunction with a hoist to remove an engine from a chassis?

A) slings
B) chains
C) spreader bar
D) rope

Question 8

When removing an engine from a truck chassis, what should be done to each electrical connector as it is separated?

A) cut off the connector
B) tag for later identification
C) draw a diagram of each connector and harness
D) replace each connector

Question 9

What is a T-puller used for?

A) removing a cylinder head
B) installing a water pump
C) installing a cylinder liner
D) removing a pulley from a shaft

Question 10

When removing a set of pistons from an engine, which of the following would be recommended practice?

A) remove in firing sequence
B) remove in companion pairs
C) remove from front to back
D) remove from back to front

Question 11

Before attempting to pull a piston from a cylinder bore, which of the following is recommended?

A) remove the crankshaft
B) pull piston through the bottom of the liner
C) clean up the liner carbon ridge
D) remove the main bearing cap

Question 12

What should be used to lift a crankshaft from an inverted cylinder block?

A) yoke with rubber conduit over throw hooks
B) wire braided slings
C) hemp braided rope
D) heavy duty chain

Question 13

What should be done with a set of main and rod cap bearings on removal from an engine?

A) dispose of in scrap metal container
B) tag by location for inspection
C) crossover to next oversize value
D) store in a sealed container

Question 14

Which of the following components does NOT require magnetic flux testing during an engine overhaul?

A) camshaft
B) engine cylinder block
C) connecting rods
D) crankshaft

Question 15

When rebuilding an engine, which of the following is best practice regarding the cylinder block?

A) immerse in a soak tank filled with alkaline solution
B) hose down with detergent and water
C) glass bead blast
D) wash with a power washer

Question 16

What is a master bar used for?

A) checking cylinder bore
B) measuring rocker shaft bore
C) checking cylinder block line bore
D) measuring flywheel concentricity

Question 17

What is Tempilstick crayon used for?

A) timing the gear train
B) displaying gear tooth contact
C) marking engine parts
D) measuring temperature

Question 18

When a flywheel housing is reinstalled to an engine cylinder block, which of the following is recommended?

A) chase the bell housing fastener threads
B) indicate the housing concentricity
C) mike the intermediate plate drive lugs
D) use new housing capscrews

Question 19

When checking connecting rod side play, which of the following tools is required if you are using the recommended method?

A) dial indicator
B) micrometer
C) a thickness gauge
D) pair of equal sized thickness gauges

Question 20

When indicating a flywheel housing you measure 0.004 inches positive and 0.003 inches negative through one revolution. What is the total indicated runout (TIR)?

A) 0.001 inches
B) 0.012 inches
C) 0.007 inches
D) 0.014 inches

Question 21

When indicating a flywheel housing for concentricity to the crankshaft, which of the following reference points on the flywheel face and sequence would produce reliable results?

A) N, S, E, W
B) E, W, N, S
C) TDC and BDC
D) NW, SW, SE, NE, NW

Question 22

When a flywheel housing measures out-of-spec while performing flywheel housing concentricity runout measurements, which of the following would represent the minimum level of repair required?

A) Replace the flywheel
B) Replace the flywheel housing
C) Replace the cylinder block
D) Reposition the flywheel housing

Question 23

Technician A says that top dead center (TDC) is simply the point at which a piston stops during its upward travel. Technician B says that piston TDC is the exact midpoint that occurs between the completion of an upstroke and the beginning of a downstroke. Who is correct?

A) Technician A only
B) Technician B only
C) Both A and B
D) Neither A nor B

Question 24

What must be used to loosen and torque pipe nuts such as those found on injector lines?

A) adjustable wrench
B) combination wrench
C) crows foot wrench
D) line wrench

Question 25

What is the most commonly recommended installation medium for injector O-rings before installation?

A) nothing
B) engine oil
C) lithium grease
D) never-seize

Question 26

What should be used to align the cylinder heads on an engine with multiple heads before torquing the cylinder head bolts?

A) machinist's straight edge
B) dial indicator
C) plastigage
D) depth micrometer

Question 27

Which injector sleeve material is least likely to produce cylinder head leakage?

A) Stainless steel
B) Ceramic
C) Copper
D) Silicone

Question 28

You are performing a cylinder block warpage test using a straightedge and 0.003 thickness gauge: the straight edge is placed corner to corner diagonally and the gauge will not pass under the straightedge at any point. Which of the following should be true?

A) cylinder block should be replaced
B) cylinder head should be replaced
C) cylinder deck should be milled
D) deck warpage is within spec

Question 29

Which type of cylinder head injector sleeve would be more likely to leak coolant into the engine cylinder?

A) stainless steel
B) copper
C) integral
D) composite

Question 30

What would happen if you mismatched a cracked rod cap with the rod assembly?

A) nothing, so long as the fasteners are torqued to spec
B) the cap and big end would not abut
C) the cap would fracture
D) the rod stem would fracture

Question 31

Technician A says that rod side play must be checked with thickness gauges on any rod that does not use fractured rod technology. Technician B says that cracked rod technology enables perfect cap to rod alignment so measuring rod sideplay on reassembly is not required. Who is correct?

A) Technician A only
B) Technician B only
C) Both A and B
D) Neither A nor B

Question 32

When installing piston packs to a diesel engine, which of the following should be avoided whenever possible?

A) lubing the ring belt with engine oil
B) use of a tapered clamp ring compressor
C) use of a tapered cylindrical ring compressor
D) use of a multi-purpose band type ring compressor

Question 33

What would most likely result if an engine was reassembled with one conn rod with a weight class two increments over specification?

A) nothing, this should be OK
B) dropped rod
C) unbalanced engine
D) crankshaft failure

Question 34

Technician A says that Ferrotherm articulating pistons are a good reuse bet providing they are properly inspected before reassembly. Technician B says that forged steel trunk Monotherm pistons are a poor reuse risk even when they appear OK on inspection. Who is correct?

A) Technician A only
B) Technician B only
C) Both A and B
D) Neither A nor B

Question 35

While checking main bearing clearance on an inverted diesel engine, the strip of Plastigage under one main shows notably more squish than the remaining mains. What does this likely indicate on this main bearing?

A) excess bearing clearance
B) insufficient bearing clearance
C) thrust washer is integral with this main
D) worn-out section of Plastigage

Question 36

Technician A says that when a counterbore is machined into the cylinder block, the deck must also be machined. Technician B says that when a cylinder block deck is machined, the cylinder counterbores should be recut. Who is correct?

A) Technician A only
B) Technician B only
C) Both A and B
D) Neither A nor B

Question 37

Which of the following explains why modern cylinder blocks are more subject to torque twist than those of a generation ago?

A) cylinder pressures are higher
B) cylinder blocks are much lighter
C) engines are more powerful
D) all of the above

Question 38

Technician A says that when there is visible thrust surface wear on a diesel engine crankshaft, the recommended solution is to replace the crankshaft. Technician B says that when the oil seal surfaces are worn, a crankshaft can usually be repaired. Who is correct?

A) Technician A only
B) Technician B only
C) Both A and B
D) Neither A nor B

Question 39

What is usually used to check the aim of piston cooling jets?

A) laser beam
B) plumb bob
C) perspex template and rod
D) vice grips