This document summarizes maintenance work performed on an engine. It describes removing the cylinder head, pistons, and cylinder liners for inspection and repair. Key steps included draining systems, loosening fasteners, lifting components, and inspecting parts for damage. Cylinder liners were honed and faced to improve sealing, and connecting rods were tested for cracks. Reassembly involved reinstalling components in reverse order and reconnecting lines.

2. Engine make : DEUTZMWM
Engine type : BV 16M640
Power : 6590kw

3.  Overdue the running hours.
 Water leak on the engine block in to the
sump.
 Seize the liner or piston.
 Seize the big end bearing.

4.  This is the document that can prove the
work we are doing in the engine is
permitted.
 This document describes the work doing.
 Contains the all the isolations made.
 signatures of the watch keeper and
maintenance engineer prove the working
conditions are clear.

5. Working environment.
 The engine was allowed to cool down.
 Crankcase doors were opened.
 Proper ventilation was arranged with air
blowers.

6. cylinder head.
 Piston was take to its compression tdc
position.

7.  Jacket water system was drained.
 Close valves and drain all lube oil and
fuel oil pipes.
 Cylinder head tappet cover was
removed.
 all the piping were disconnected from
the cylinder head. e.i high pressure
fuel, injector nozzle cooling, leak off
fuel, starting pilot air, charge air bello
rings, starting air, exhaust gas, ht water
in and out, rocker arm lubrication pipes
and also the indicator cock and the
exhaust gas thermo couple.
 Tappet screws were loosened and the
pushrods and covers were pulled out.

8.  All the cylinder
head studs’ thread
was cleaned.
 Four hydraulic
jacks were
mounted safely on
the studs.
 Hydraulic cables
were
connected, jacks
were tightened
and the
clearances were
kept.

9.  Jacks were operated with all the safety
steps up to 900 bar.
 The jack operator must wear eye
protectors and hand gloves in case of
accidents could occur.
 Round nuts were loosened with a Tommy
bar.
 Hydraulic pressure was released and the
same steps were followed with the
remaining 4 studs.
 Cyl. head lifting tool was secured and
the head was lifted slowly with a chain
block.

10.  The wear edge was the removed with a power
buff. Otherwise the cyl liner will come out
together with the piston.
 In some liners the fire rings are fitted, so it has
to be removed first before the piston.
 The bolt holes on the piston crown was cleaned
with wd40 and a tap. This is where the piston
lifting tool get secured to.
 Piston was taken to its compression tdc
position.
 lifting tool was secured to the piston.
 Loose the big end keeper holding annular nut by
raising hydraulic pressure to 1020 bar.
 Bottom annular nuts were loosened and take
out with the waisted studs.
 The slider was placed under the bearing half.
 The remaining tow annular nuts were also taken
out with the waisted studs.
 The big end bottom half was taken out from the
the crank case with the slider.

12.  A chain block was attached to the lifting
tool and the piston was lifted slowly. The
big end should be observed because it
may hit the cyl liner or the crank pin.
 Once the piston was taken out, the rings
were removed and inspected.

13.  Cyl liner pulling tool was secured to the
liner.
Removing cyl liner.

14.  When the liner is pulled the remaining jacket
water may enter the crank case. A suitable
arrangament has to be made to prevent it.
 The liner was loosened and pulled out.

15. Inspections.
 Dp test was run on the cyl line after
cleaning it.
 An ovelity check was done for the liner and
after liner horning and face grinding was
done.
 Engine block was also cleaned and checked
for cracks and damages.
 In case present of damages, they have to be
filled with JB Weld or using any other
suitable material.
cyl liner.

16.  When the the piston moves up down in the
cylinder, the cylinder surface get warned due to
the friction between liner and piston rings.
 So to obtain a better lubrication between rings
and the cyl liner, the liner has to be horn.
 The horning process makes small smooth grove
pattern inside the liner surface.
cyl liner horning.

18.  The liner was placed and mounted to the horning
machine.
 Grinding pieces were widened so as to touch the
liner bore and locked.
 The grinding tool was moved downward and
checked the clearances.
 Guide tool was entered to the liner.
 Sensor tool was mounted.
 horning machine was loaded by turning handle
then turn for pneumatic operation from manual
operation by operating valve.
 Open the two valve together which valve is
grinding piece with guide rotating valve and
grinding piece up and down moving valve. full
open the up and down moving valve and open the
guide rotating valve as get correctly cutting
angle .

19.  Cutting angle must be 120 degree it was
settled visually by opening tool rotating
valve.
 We horning until remove damage as well as
apply the diesel on the grinding surface
while horning.
 Horng the liner for that firstly using rough
grinding piece and secondly smooth
grinding piece.
 Stop the horning machine finally we must
close valve together, rotating movement
and up and down movement.

20.  Loose the above sensor and turn handle for
manual operation of the machine.
 Release the load on the grinding machine.
 Move the guide tool with grinding piece on
the up ward away from the liner.
 Remove the liner on the base of the trolley.

21.  Liner face must be seated on the liner
base with the sealing ring. we applied
sealing ring from 1.5 to 2 mm thickness.
we selected required ring by calibration
liner face height and base height on the
head after the liner horning and head
lapped. if not seated liner and head with
sealing ring can be leak gas on the unit.
because liner face grinding is very
important thing.

22. Firstly select the liner for face grinding by
using digital venire caliper.
Place the liner on the wood plate.
Place the grinding machine on the liner.
We must concern the placing
machine, because alignment ring must be
enter in to the liner correctly.
Connect the service air line on to the
grinding machine.

23.  Cylinder liner face means the seat which
seats with the cyl head.
 This has to be in good condition, if not
exhaust gas could escape through the non
sealing area.
 So to prevent happening that, a good sealing
surface should be given to the liner face by
grinding.
 This can be done either with a grinding
machine or with a lapping tool.

25.  After the horning and grinding the liner has to
be calibrated.
 In the calibration three axial readings and
three transverse readings were taken at
different heights.

27. Connecting rod crack testing
procedure. Magnet particle test is done on the con rod for
the test.
 Bottom half was attached and tightened with
hydraulic jacks with a pressure of 900 bars.
 The inner big bearing side was cleaned by
using sand paper and cleaner.
 Detection cleaner was applied for remove dust
particles.
 Spray the magnaflux liquid on the relevant
surface and keep uv York can identify crack on
the surface. Cracks appear as yellow lines
some times.
 Keep york vertically to the surface for identify
a crack. Crack located horizontally or near
horizontally for magnetic field.

28. • Ovality of the big end was then measured with an
inside micro meter.

29. Crank pin.
•The crank pin was inspected for damages and
scratches.
•If there are scratches are present, the y have to
be removed by polishing.
•If the damage is bigger then we have to grind
the pin and reduce the diameter.
•This is a long time taking procedure.
•A specially designed pneumatically operated
tool was used for the job.

33.  Enter the “o” ring on the liner.

34.  Enter the liner in to the engine block.
 Set the piston with the big end bearing.
 Set the fire ring.
 Place the Engine head applying gasket
and sealing ring.
 Connect the all removing line.
 Finally set the tappet.

35. Thank you.
Prepaired by,
A.G.G.A.Amukotuwa
mm/09/7788