Wednesday, July 05, 2006

Cat 3116 Diesel - Engine Removal

This CAT 3116 Diesel Engine has failed because of an exhaust seat on #5 cylinder that collapsed and the fragments caused damage to the cylinder wall. The next operation is to remove the engine assembly and strip down the block so the cylinder can be repaired.

The Cat 3116 block deck surface has to be secured with a special plate fastened down with head bolts so the block does not warp while boring is performed.
Here you can see the scores running down the cylinder wall. Bits of broken metal that came from the exhaust valve seat lodged between the piston and cylinder. The turbo will have to be sent out for repair as well since the failure was on the exhaust side. Fragments will have went through the turbine wheel[exhaust side of the turbo] which runs on a very close tolerance.

Once the block is standing up resting on the flywheel housing the pistons are easily removed. All accessories have been removed including the oil cooler, governor, front gear housing ,camshaft and follower assemblies.
The cylinder head was removed while in the bus frame. We built a lifting bracket to fit over 2 head bolt holes and picked up shorter grade 8 bolts so the block could be hoisted out of the frame.

Once the pistons, flywheel housing and main bearing caps have been removed we used a fibre lifting strap to hoist out the crankshaft.

Out comes the crankshaft and the block will be sent to the machine shop for repair. They will measure the cylinder wear and see if they can machine damaged cylinder and press a dry sleeve bringing #5 bore back to standard.
They will hot tank the block and later press in new camshaft bushings.
Stay in touch with this blog as I reassemble our CAT 3116 Diesel Engine.

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