Cylinder Block Inspection/Repair
CYLINDER BLOCK INSPECTION/REPAIRCylinder Block Inspection
1. Measure the cylinder bore at the top and bottom. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder taper; bore the cylinder to the next oversize.
2. Measure the cylinder bore in two directions. The difference is the out-of-round. Verify the out-of-round is within the wear limit and bore the cylinder to the next oversize limit.
3. Use a straight edge and feeler gauge to inspect the head gasket surface for flatness. If the cylinder block is distorted, resurface the cylinder block within specification.
^ The head gasket surface is measured in six straight line directions for flatness.
Cylinder Block Repair
Cast Iron Porosity Defects
Caution
^ Do not attempt to repair cracks.
^ Do not attempt to repair areas where temperature will exceed 260°C (500° F).
1. Repair porosity defects with an epoxy sealer.
(1). Clean the surface to be repaired to a bright, oil-free metal surface.
(2). Chamfer or undercut the repair area to a greater depth than the rest of the cleaned surface. Solid metal must surround the area to be repaired.
(3). Apply the epoxy sealer and heat-cure with a 250 watt lamp placed 254 mm (10 inch) from the repaired surface or air dry for 10-12 hours at a temperature above 10°C (50°F).
(4). Sand or grind the repaired area to blend with the general contour of the surface.
(5). Paint the surface to match the rest of the cylinder block.
Cylinder Block Honing
Caution
^ After the final honing and prior to checking the piston fit, thoroughly clean the cylinder bore with a detergent and water solution. Then lightly coat the cylinder bore with Premium SAE 1OW-30 Motor Oil.
^ When honing the cylinder bores, use a lubricant mixture of equal parts of kerosene and Premium SAE 1OW-30 Motor Oil.
Note
^ Before any cylinder bore is honed, all main bearing caps must be installed so that the crankshaft bearing bores will not become distorted.
^ To correct taper out-of-round, bore the cylinder block.
^ Honing should be done when fitting new piston rings or removing minor surface imperfections.
1. Hone with the Engine Cylinder Hone Set, at a speed of 300-500 rpm and a hone grit of 180-200, to provide the desired cylinder bore surface finish of 18-38 AA.
Caution
^ If these procedures are not followed, rusting of the cylinder bores may occur.
2. Clean the cylinder bores with soap or detergent and water.
3. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
4. Use a clean, lint-free cloth and lubricate the cylinder bores.
^ Use Super Premium 5W-30 SAE Motor Oil.
Cylinder Block Core Plug Replacement
1. Drill a small hole in the center of the engine block, then use the Locknut Pin Remover T78P-3504-N or equivalent to remove the engine block plug.
2. Inspect the cylinder block plug bore for any damage that would interfere with the proper sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug.
Note
^ Oversize plugs are identified by the "OS" stamped in the flat located on the cup side of the plug.
3. Coat the engine block plug and bore lightly with an oil-resistant (oil galley) Study and Bearing Mount and install the engine block plug.
Cylinder Block Core Installation [Cup Type]
Caution
^ Do not contact the flange when installing a cup-type engine block plug. This could damage the sealing edge and result in leakage.
^ When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore.
1. Use a (1) cup-type core plug replacer tool to seat the (2) cup-type engine block plug.
Cylinder Block Core Installation [Expansion Type]
Caution
^ Do not contact the crown when installing a cup-type engine block plug. This could expand the plug before seating and result In leakage.
1. Use an (1) expansion-type core plug replacer tool to seat the (2) expansion-type engine block plug.