21. Engine Block Cleaning and Inspection

Engine Block Cleaning and Inspection

Special Tools

* EN-8087 - Cylinder Bore Gauge

* GE-7872 - Magnetic Base Dial Indicator

For equivalent regional tools, refer to Special Tools Special Tools.





1. Clean the sealing material from the gasket mating surfaces (2) with a suitable tool (1).

2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.

3. Flush the engine block with clean water or steam.

4. Clean the oil passages.

5. Clean the blind holes.

6. Inspect the cylinder bores for glazing. If the bore is glazed but otherwise serviceable, refer to Deglazing Procedure in Cylinder Boring and Honing (LAF, LEA, or LUK) 22. Cylinder Boring and Honing (LAF, LEA, or LUK).

7. Spray the cylinder bores and the machined surfaces with engine oil.

8. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to Thread Repair 43. Thread Repair.





Note:
Do not attempt to machine the lower crankcase to engine block surfaces.

9. Use a straight edge (1) and a feeler gauge (2) to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.

10. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.





11. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side with a suitable tool (1).





12. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side with a suitable tool (1).





13. Inspect the mating surfaces of the transmission face.

Caution:
A broken flywheel may result if the transmission case mating surface is not flat.

14. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses:

1. Temporarily install the crankshaft and upper bearings. Measure the crankshaft flange runout using the GE-7872 - dial indicator (1)

2. Hold the gauge plate flat against the crankshaft flange.

3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.

4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in).

5. Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).

6. Remove the crankshaft and bearings.





15. Install the bed plate and bolts. Tighten the bed plate bolts to specification.

16. Inspect the crankshaft main bearing bores. Use the EN-8087 - gauge (1) to measure the bearing bore concentricity and alignment. Refer to Engine Mechanical Specifications (LAF, LEA, or LUK) Engine Mechanical Specifications (LAF, LEA, or LUK).

17. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.

18. Remove the bed plate.

Measuring Cylinder Bore Diameter





1. Measure the cylinder bore diameter 37 mm (1.457 in) from the deck face using the EN-8087 - gauge.

2. Compare your results with the Engine Mechanical Specifications (LAF, LEA, or LUK) Engine Mechanical Specifications (LAF, LEA, or LUK). If the cylinder diameter exceeds the specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service. Refer to Cylinder Boring and Honing (LAF, LEA, or LUK) 22. Cylinder Boring and Honing (LAF, LEA, or LUK).

Measuring Cylinder Bore Taper





1. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 13 mm (0.510 in) below the deck surface (1) and record your measurement.

2. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 100 mm (3.938 in) below the deck surface (2) and record your measurement.

3. Calculate the difference between the 2 measurements. The result will be the cylinder taper.

4. Compare your results with the Engine Mechanical Specifications (LAF, LEA, or LUK) Engine Mechanical Specifications (LAF, LEA, or LUK). If the cylinders exceed the specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service. Refer to Cylinder Boring and Honing (LAF, LEA, or LUK) 22. Cylinder Boring and Honing (LAF, LEA, or LUK).

Measuring Cylinder Bore Out-of-Round





1. Measure both the thrust and non-thrust cylinder diameter at 13 mm (0.510 in) below the deck surface (1). Record your measurements.

2. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the upper end of the cylinder.

3. Measure both the thrust and non-thrust cylinder diameter at 100 mm (3.938 in) below the deck surface (2). Record your measurements.

4. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the lower end of the cylinder.

5. Compare your results with the Engine Mechanical Specifications (LAF, LEA, or LUK) Engine Mechanical Specifications (LAF, LEA, or LUK). If the cylinders exceed these specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service. Refer to Cylinder Boring and Honing (LAF, LEA, or LUK) 22. Cylinder Boring and Honing (LAF, LEA, or LUK).