CYLINDER BLOCK INSPECTION

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CYLINDER BLOCK INSPECTION CLEANING

• Chapter 11
• Classroom Manual
• Page 259
• Lab Manual
• Page 269

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CHAPTER OBJECTIVES

• Analyze wear and Damage to the Cylinder Block.
• Select Perform appropriate repairs.
• R R cam bearings, gallery plug, core plugs.
• Explain theories of cylinder wall finishes.

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CHAPTER INTRODUCTION

• Blocks can usually be reused.
• All will need cam bearings, Soft plugs, and
  Cleaning.
• Most will have cylinders bored oversize.
• Some will need the Deck resurfaced.
• A few will need Align Boring of the Main Bearings.

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CLEANING THE BLOCK

• The block must be thoroughly cleaned.
• All core plugs, oil gallery plugs, BEARINGS,
  other parts -
• Must be removed before hot tanking.
• Flush thoroughly to remove caustic solution from
  water jackets.
• Lubricate bores - Check for cracks.

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INSPECTION

• Measure cylinder bores for taper out-of-round.
• Measure decks for straightness.
• Measure main journals for straightness.
• Inspect all threads, DNR.
• Magniflux for cracks.

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OIL AND WATER PLUGS

• Oil galleries must be cleaned with a brush after
  tanking.
• Pipe threads are tapered thread.
• You can leave one end in place if necessary.

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DECKING THE BLOCK

• Do not make surface to smooth.
• Remove all nicks and burrs.
• Blocks can be milled or ground to true deck
  surfaces.

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CHECKING THE DECK
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PISTON CLEARANCE

• Dana Recommends .0015 piston to wall clearance.
• Clearance is built into piston.
• Better to hone cylinder to each piston.
• Can be checked with a feeler gauge, 90 to wrist
  pin.
• Dial bore gauge is more accurate.

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CHAMFERING THE CYLINDER

• The chamfer is removed during the boring process.
• A chamfer is necessary to aid in ring
  installation.
• Use a chamfering cone and a drill.
• DO NOT USE A RIDGE REAMER.

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CYLINDER SLEEVES

• A deeply scored, rusted or cracked cylinder can
  be sleeved
• Crack can not extend to the top or bottom of the
  cylinder.
• Dry sleeve has interference fit of .0005 per
  inch.
• Sleeve may be driven or pressed in.
• Sometimes a step is left at the bottom.

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MAIN BEARING CAPS

• Cylinders are bored with Main caps torqued in
  place.
• Main bearings are bored with caps torqued in
  place.
• Main caps are NOT interchangeable.
• Heavy-Duty or High Performance engines use 4 bolt
  caps.

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MAIN BORE ALIGNMENT

• Heating and cooling cycles can cause block
  warpage.
• .0010 feeler gauge and strait edge.
• When a journal is blued the block must be align
  bored.
• Align bore or align hone.

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LIFTER BORES

• Lift bores must be clean to ensure they will
  spin.
• Bores can be cleaned with a brake hone.
• Check for oversize bores.
• Oversize bores with standard lifters will cause
  low oil pressure.

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FINAL BLOCK PREPARATION

• Chase head bolt holes before cleaning.
• Clean the block with soap and HOT WATER.
• Use eye protection, to blow out bolt holes.
• If block is milled or decked, bolt holes may be
  chamfered.

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INSTALL OIL GALLERY CORE PLUGS

• Oil gallery plug may be coated with sealer or
  Teflon tape.
• Press in plugs are cross staked.
• Clean core plug holes with sandpaper before
  installation.
• Use a tool that is 1/8 smaller than inside
  diameter of plug.
• Install just past the chamfer on block.

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The End