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Troy-Bilt TB 42

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Orayen
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2019/05/12 16:45:31 (permalink)
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Troy-Bilt TB 42

I'm working on a Troy-Bilt TB 42 mower with a 4P90HUB engine. The engine was hard to start, but when it did start it sounded healthy. However, it would lose power when put under a load. A previous mechanics replaced the carburetor. That worked for a while. I noticed the engine had very little compression. A compression tester measured 0 psi. I took the valve cover off and injected air into the cylinder through the spark plug hole. Oil started shooting out from around the push rods. No air seemed to leak out from the carburetor or exhaust. I removed the cylinder head thinking it was a blown head gasket. Pictures of the gasket are attached. It doesn't look terrible. The cylinder shows no sign of scoring. I'm not sure what to do next. Any advice?

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    AVB
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    Re: Troy-Bilt TB 42 2019/05/13 02:28:34 (permalink)
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    Yes oil and air would come out the push rod galley. It would ring blow-by which all engines have. Now the percentage of this leakage is what important. Most OEM spec no more than 20% but I have work on some that this is as high 40%.
     
    The question is why you got zero compression. Have you verified that the piston is moving up and down in the cylinder? As you should gotten something; unless, the piston rod is broken. Compression should be in the range of 55 - 80 PSI (3.8 - 5.5 Bar) for the P90. Now it does take a compression design for small engines as automotive gauges may have too strong of a check valve (scharder valve) to allow proper compression readings.
     
    Btw the head gasket does shows that it appeared to have been leaking so check the head for warpage. No more than .003" is allowed on most engines with all metal head gaskets. The cylinder does appear quite worn too as I see a shiny area and no honing crosshatch pattern. Service limit is 90.25mm (normal diameter is 90.01-90.02mm) so this a max wear of .009" for the cylinder with zero taper and .008" out round. No oversize piston and rings sets are available for this so it would not be rebuildable if worn out. This what you get with a Chinese built engine.
     
    I have only a handful of this engines in the shop. One with snapped rod and one with seized engine mounting bolts, the rest were just carburetor problems.
    Orayen
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    Re: Troy-Bilt TB 42 2019/05/13 10:44:00 (permalink)
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    Thank you very much for your detail suggestions. This is exactly what I was hoping for. 
     
    You are right about the compression tester, it's an automotive gauge. I noticed that there was very little difference in compression with the spark plug in or out, so the zero reading didn't surprise me. Yes, the piston is moving. The piston rod is not broken.
     
    It sounds like the next step is to measure the cylinder bore, but I don't have the proper tools. I'm just a hobbyist. My day job is a math professor. I'm the unofficial faculty lawn mower repair guy. I do mostly tune-ups and minor repairs. This job may have been too much for me, but I'm enjoying the learning process.
     
    You're also right about the crosshatching; I don't see any. I'm tempted to replace the head gasket and see what happens, but I'm afraid I'd just be wasting $30. Any thoughts?
     
    Do you happen to have a used engine to sell? I've got a new carburetor and the rest of the engine is in good shape. I live in Nebraska.
    post edited by Orayen - 2019/05/13 15:36:01
    Orayen
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    Re: Troy-Bilt TB 42 2019/05/14 10:20:57 (permalink)
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    I was able to measure the cylinder diameter. It was well less than the service limit of 90.25 mm. I think next I'll pull out the piston and check the rings.
    Orayen
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    Re: Troy-Bilt TB 42 2019/05/15 23:39:21 (permalink)
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    I was able to get the piston out. The rings are in terrible shape. I will replace them and the head gasket and hope for the best.
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