Parts Reuse Guidelines
Parts Reuse Guidelines
Parts Reuse Guidelines
Bulletin No 3810303
Table of Contents
1. Introduction
2
1. Introduction.
Significant savings can be realized by reusing parts during engine
repair. Visual inspection of many of the parts is adequate to
determine if the component can be reused without compromising
the quality of a repair.
3
2. Bearing Reuse Guidelines
Contents of this section
5
Loss of overlay / copper exposure
6
Loss of overlay / copper exposure
This photograph illustrates Light copper exposure near Slightly more copper
a loss of overlay. The the edges of the bearing. exposure but the bearing
bearing material is not This bearing is acceptable is still acceptable for
visible. This bearing is for reuse. reuse.
acceptable for reuse.
7
Loss of overlay / copper exposure
8
Loss of overlay / copper exposure
9
Abrasions or scratches from coarse
particles
Bearing shell inspection can show a variety of types and
severity of abrasions or scratches.
10
Abrasions or scratches from coarse
particles
This photograph illustrates Do not routinely discard all This photograph illustrates
bearings with scratches. Light
light, smooth scratches. scratches that are visible only or
a bearing with heavier
The scratches expose the that can be felt with fingernail but scratches. The scratches
copper but are not deep. do not have raised or ragged do not have raised or
The bearing is acceptable edges are acceptable for reuse. ragged edges and are not
for reuse. This photograph illustrates a deep. The bearing is
bearing with several light acceptable for reuse.
scratches. The bearing is
acceptable for reuse.
11
Abrasions or scratches from coarse
particles
12
Embedded material
13
Embedded material
The bearing illustrated in This bearing exhibits If large amounts of soft material or
an abrasive material is embedded,
this photograph is slightly more scratches and the bearing is not acceptable for
acceptable for reuse. embedded particles, but reuse. Abrasive material
still acceptable for reuse. embedded in the bearing may cut
scratches or grooves in the
crankshaft.
This photograph illustrates a
bearing that has an unacceptable
amount of embedded material.
This bearing is not acceptable for
reuse.
14
Embedded material
15
Bearing wiping
16
Bearing wiping
This photograph illustrates Wiping damage occurs quickly This photograph illustrates
an early indication of and the bearings will be the maximum amount of
wiping as shown by destroyed if the conditions wiping that is acceptable
exists for more than a few
polishing at the center and for reuse.
revolutions of the crankshaft.
edges of the bearing. This
bearing is acceptable for This photograph illustrates a
reuse. slightly heavier amount of
polishing, but the bearing is
acceptable for reuse.
17
Bearing wiping
18
Cold start seizure
19
Fatigue damage
20
Fatigue damage
Bearing that show any This photograph illustrates Fatigue of the steel back
amount of fatigue damage fatigue that has been of the bearing will show as
are not acceptable for initiated at the edge of the cracking of the steel back.
reuse. deep scratches. This This type of failure can be
bearing is not acceptable the result of low bearing
for reuse. crush or connecting rod or
main bearing bore
geometry.
21
Fatigue damage
23
corrosion
24
Fuel/coolant dilution
25
Fuel/coolant dilution
This bearing exhibits black This bearing has a broad Bearings that have been operated
with fuel in the oil will have a
discoloration of the band of black discoloration slightly green or brown hue. The
overlay, but is acceptable of the overlay at both condition can be caused by
for reuse. edges of the loaded overfueling, excessive idle
bearing area. The bearing periods, injector o-ring leakage or
incomplete combustion.
is acceptable for reuse.
This bearing is acceptable for
reuse.
26
Fuel/coolant dilution
27
Overlay fatigue
Overlay fatigue occurs in the loaded area of the bearing.
It shows as a series of irregular and sometimes inter-
connecting dark lines. Overlay fatigue is not detrimental
to the function of the bearing and does not extend
deeper than the lead/tin or lead/indium coating.
28
Overlay cavitation
Overlay cavitation is caused by the dynamics of the oil
film as it moves around the crank and bearing joint. This
condition appears only on the unloaded half of the
bearing set. The area of cavitation will vary in size and
outline and is normally appears only in the bearing
overlay material.
. These bearings are
acceptable for reuse.
29
Installation damage
30
Installation damage
This photograph illustrates This photograph shows the This photograph illustrates
that an object was reverse side of the bearing a bearing that was
between the bearing back previously illustrated. incorrectly installed. The
and the bore for the tang was not correctly
bearing thus causing aligned with the slot in the
deflection of the bearing. connecting rod.
31
Installation damage
32
3. Block Counterbore Reuse
Guidelines
Contents of this section
34
Counterbore inside diameter wear
The press fit (A) between the The machining marks left Wear areas are indicated by
counterbore inside diameter and polishing on the inside
the liner flange helps prevent
in the counterbore can be
used to determine if the diameter (ID) surface.
movement (B) of the liner and
Significant wear is indicated
subsequent wear of the flange counterbore is acceptable
ledge and counterbore seat (C). by a lack of machining marks
for reuse. on the surface of the inside
If there is wear, it usually occurs in diameter in the press fit area.
line with the crankshaft.
This block is acceptable for
A worn counterbore seat will allow reuse, no appreciable wear
coolant leak. evident.
35
Counterbore inside diameter wear
The degree of wear is The ID of this counterbore The wear (no machining
visually detectable by the has a small polished area marks) on the ID of this
absence of machining which is less than ½ inch in counterbore exceeds ½
marks in the polished width. inch.
area.
This counterbore is This block is not
The limit for worn away acceptable for reuse. acceptable for reuse
marks is ½ inch. without a re-machining the
counterbore ID.
36
Counterbore seat wear
Leaks path are created by This close-up view of the The degree of wear is visually
detectable by absence of
both seat wear (polishing) damage area reveals the machining marks in the polished
and pitting. pitting. area.
Pitting on the liner seat is This cylinder block requires NOTE: The tool marks (if any) on
previously re-machined seats will
not acceptable. counterbore machining be radial instead of concentric
before it can be reused. ridges.
38
Counterbore ledge cracks
39
Capscrew hole cracks / Water passage cracks
Cracks which extend from Cracks which extend into Cracks which extends
the counterbore wall to the the threaded portion of the horizontally from
capscrew hole are hole require salvage with a counterbore ledge to the
acceptable for reuse if it blind end thread insert. water passage require
does not extend into sleeving of the water
threaded portion of hole. passage.
40
4. Cylinder Liner Reuse
Guidelines
Contents of this section
• Bore wear.
Liner bore scoring.
Liner bore scratches.
• Crevice seal groove erosion.
• Flange crack.
• Flange wear (Ledge).
• Flange wear (Outside diameter).
• Liner corrosion.
• Liner pitting.
42
Bore wear
Liner are manufactured with a This liner has only a small amount This liner exhibits limited
very straight, round cylinder bore of light polish. moderate polish.
to provide a sealing surface for the
piston ring. Light polish is defined as a bright, Moderate polish is defined as a
shiny worn area with a gray hue. A bright, mirror finish in the ring
Wear of the bore is detectable by light amount of Lubrite coating will travel area and has very light
the degree of polishing visible in remain in the heavy etch pattern traces of the hone marks.
the bore. will be gone. The hone marks are
still intact. This liner is acceptable for reuse.
This is a new liner.
This liner is acceptable for reuse.
43
Bore wear / Liner bore scoring
This liner has heavy polish In addition to the obvious heavy This liner has severe
polish, this liner has scoring
present in over 20 percent indicated by the dark spots in the
scoring. Liners with any
of the piston of the piston upper ring reversal area. indication of scuffing or
ring travel area. scoring are not acceptable
A scored surface interrupts ring for reuse.
sealing. If the damaged surface
The liner is not contains embedded carbon, it will
acceptable for reuse cause new ring to wear rapidly. This liner is not
acceptable for reuse.
This liner is not acceptable for
reuse.
44
Liner bore scratches
45
Flange wear (outside diameter)
The press fit (A) between the Wear on the OD of the flange is
The degree of wear is visually
outside diameter (OD) of the liner indicated by small polished area on
detectable by the absence of
flange and the block helps to this liner. machining marks in the
prevent movement (B) of the liner
and subsequent wear of the flange NOTE: The polished area on
polished area.
ledge and counterbore seat (C). reusable liner should be positioned
at a right angle to the crankshaft so The left side of the flange in
If there is wear, it usually occurs in an unpolished area is installed in this close-up view reveals
line with the crankshaft. line with the crankshaft. worn away machining marks.
A worn counterbore seat will allow This liner is acceptable for reuse.
coolant leak.
46
Flange wear (outside diameter)
The limit for worn away The wear (no machining The wear on this flange is
machining marks is 1/2 marks) on this flange is greater than one half inch.
inch. less than ½ inch.
A liner with this amount of
wear is not acceptable for
A liner with this degree of reuse.
flange wear is reusable.
47
Flange wear (ledge) / Flange cracks
Wear is indicated by absence of Wear (no machining marks) Flange cracks are
machining marks in the polished area.
and pitting on this flange ledge unacceptable. Cracks are
The limit for worn away machining is greater than ½ inch. most noticeable on the
marks is ½ inch. internal surface of the liner,
NOTE: The polished area on reusable This liner is not acceptable normally ½ inch down from
liners should be positioned at a right for reuse. the top of the liner.
angle to the crankshaft so when the
liner is installed, an unpolished area is
in line with the crankshaft. Do not reuse a liner with
flange cracks.
48
Liner pitting
This liner has light pitting. Reused liners having light Heavy pitting is indicated
The pitting is due to improper
pitting must be installed by a depth greater than
maintenance of the cooling with the pitting positioned half liner wall thickness.
system. Light pitting is indicated in line with the crankshaft.
by a depth less than half the liner This liner is not
wall thickness.
acceptable for reuse.
This liner is acceptable for reuse.
49
Crevice seal groove erosion / Liner corrosion
Coolant erosion of the crevice seal Erosion greater than half Corrosion is caused by
is indicated by pitting which
progresses downward from the
the crevice seal groove poor maintenance of the
top of the crevice seal groove. The width is which can caused cooling system.
limit for erosion is one-half the a coolant leak.
groove width. After all those scale is
This liner is acceptable for reuse This liner is not removed, this liner will be
providing the erosion is installed in acceptable for reuse. acceptable for reuse.
line with crankshaft.
50
5. Piston Reuse Guidelines
Contents of this section
• Carbon damage.
• Dome cracks.
• Pin bore cracks.
• Skirt damage.
52
Carbon damage
Carbon build up above the Damage extending into the The wear on this flange is
upper ring land can cause ring land will displace metal greater than one half inch.
metal to be removed from from the land into de
piston. Damage above the A liner with this amount of
groove causing loss of
ring land does not affect the wear is not acceptable for
function of the piston. piston ring sealing. reuse.
53
Dome cracks / Pin bore cracks
Cracks in the dome area of Cracks that are longer than The length of a crack in the
the piston area caused by one-half the rim width or pin bore can progress with
intense head of the cylinder cracks that extend over the continue use of the piston.
during engine operation.
rim toward the Ni-resist
Cracks shorter than one-half Pistons with pin bore cracks
the rim thickness do not affect insert are detrimental. are not acceptable for reuse.
the function of the piston.
This piston ring is not
This piston is acceptable for acceptable for reuse.
reuse.
54
Ring land damage
Piston with ring groove This piston has a worn ring This piston has erosion
damage cannot be reused. groove and is not caused by non-atomized fuel.
Generally the wear will be acceptable for reuse. Pistons exhibiting any erosion
most noticeable in the second near the ring lands are not
ring groove. A worn groove acceptable for reuse.
will have a detectable step at
the back of the groove and a This piston is not acceptable
rolled edged at the surface of for reuse.
the piston.
55
Ring land damage / Skirt damage
This photograph illustrates severe Damage to the piston skirt surface The scratch on this piston
ring land contact with the cylinder is detrimental when the damage is
liner. This is a result of either the such that it interrupts the normal
is long and deep; therefore
piston pin bore being off-center or film of oil which prevents metal-to- this piston is not
a bent connecting rod. Pistons metal contact between the piston acceptable for reuse.
exhibiting any contact damage to and the cylinder.
the ring lands are not acceptable
for reuse. The scratches on this piston
are very shallow; therefore,
Caution: Be sure to check the the piston is acceptable for
twist and bend of the connecting
rod before installing a new piston.
reuse.
56
Skirt damage