Cylinder Block Assembly: Service and Repair
COMBUSTION DECK
The distortion of the combustion deck face is not to exceed 0.010mm [0.0004 inch] in any 50.00mm [2.0 inch] diameter. Overall variation end to end or side to side 0.075mm [0.003 inch).
The combustion deck can be refaced twice. The first reface should be 0.15mm [0.0059 inch]. If additional refacing is required, an additional 0.35mm [0.0138 inch] can be removed. Total allowed refacing is 0.50mm [0.0197 inch].
A = 0.15mm [0.0058 inch] First reface
0.35mm [0.0138 inch] Second additional reface
0.50mm [0.0197 inch] Total Allowed
B = 323.00mm +/- 0.10 Standard
[12.7165 inch +/- .0039]
322.85mm +/- 0.10 First reface
[12.7106 inch +/- 0.0039]
322.50mm +/- 0.10 Second reface
[12.6968 inch +/- 0.0039]
Surface finish requirements = 1.5 - 3.2 micrometers [60-126 microinch]
The upper right corner of the rear face of the block must be stamped with a X when the block is refaced to 0.15 mm [0.0059 inch]. A second X must be stamped beside the first when the block is refaced to 0.50 mm [0.0197 inch].
Consult the parts catalog for the proper head gaskets which must be used with refaced blocks to insure proper piston-to-valve clearance.
A = Use where block deck has been refaced 0.15mm [0.0059 inch]. (two notches)
B = Use where block deck has been refaced 0.50mm [0.0197 inch]. (three notches)
CAM BORE(S)
The front cam bushing bore can be rebored to 57.740 +/- 0.018 mm [2.273 +/- 0.0007 inch] oversize. Do not bore the intermediate or rear cam bore to the front cam bore oversize dimensions. Intermediate and rear cam bores may be rebored to 57.240 +/- 0.018 mm [2.253 +/- 0.0007 inch] oversize. A surface finish of 2.3 micrometers [92 microinch] must be maintained. Not more than 20 percent of area of any one bore may be 3.2 micrometers [126 microinch].
NOTE: Camshaft bores can be repaired individually. It is not necessary to repair undamaged cam bores in order to repair individually damaged cam bores.
Install all cam bushings flush or below the front cam bore surface. The oil hole must align to allow a 3.2 mm [0.125 inch] rod to pass through freely.
CAUTION: The standard front bushing cannot be used to repair Intermediate or rear bores. Consult the parts manual for correct oversize cam bushing part numbers.
CYLINDER BORE(S) REPAIR - GENERAL
Cylinder bore(s) can be repaired by two methods.
Method 1
^ Over boring and using oversize pistons and rings.
Method 2
^ Boring and installing a repair sleeve to return the bore to standard dimensions.
^ Oversize pistons and rings are available in two sizes: 0.50 mm [0.0197 inch] and 1.00 mm [0.0393 inch].
^ If more than 1.00 mm [0.0393 inch] overbore is needed, a repair sleeve is required. It is permissible to install sleeves into individual cylinders as required. Repair sleeves can be replaced by using a boring bar to bore out the old sleeve. Do not cut the cylinder bore beyond the oversize limit. It is also permissible to overbore individual cylinders as required. Any combination of standard, 0.50 mm overbore, or 1.00 mm overbore may be used in the same engine.
CYLINDER BORE(S)
Block cylinder bores may be rebored twice before use of a repair sleeve is required. The first rebore is 0.50 mm [0.197 inch] oversize. The second rebore is 1.00 mm [0.0393 inch] oversize.
Boring Diameter Dimensions
A = 102.469 mm [4.0342 inch] First rebore
102.969 mm [4.0539 inch] Second rebore
Honing Diameter Dimensions
B = 102.020 +/- .020 mm Standard bore
[4.0165 +/- 0.0008 inch]
102.520 +/- 0.020 mm First rebore
[4.0362 +/- 0.008 inch]
103.020 +/- 0.020 mm Second rebore
[4.0559 +/- 0.0008 inch]
After boring to size, use a honing stone to chamfer the edge of the bore to Dimension C.
C = Approximately 1.25 mm [0.049 inch] X 15 Degrees
A correctly honed surface will have a cross-hatch appearance with the lines at 15 to 25 degree angles with the top of the cylinder block.
Rough hone: Use 80 grit honing stones. Finish hone: Use 280 grit honing stones.
A maximum of 1.2 micrometer [48 microinch] surface finish must be obtained.
After finish honing is complete:
^ Immediately clean the cylinder bores with a strong solution of laundry detergent and hot water.
^ After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white, lint-free, lightly-oiled cloth. There should be no grit residue present.
If the block is not to be used right away, coat it with a rust- preventing compound.
REPAIR SLEEVE INSTALLATION
If more than a 1.00 mm [0.03937 inch] diameter oversize bore is required, the block must be rebored and a repair sleeve installed. The repair sleeve must be bored and honed to a finished size of 102.020 +/- 0.020mm [4.0165 +/- 0.0008 inch] diameter. A standard diameter piston and a service piston ring set must be used.
Block Rebore for Repair Sleeve
A = 104.500 + .015mm - 0.000mm [4.1142 + 0.0006 - 0.000 inch]
B = 6.35mm [0.250 inch]
Repair Sleeve Part No.4429166
After machining the block for the new repair sleeve, thoroughly clean the bore of all metal chips, debris, and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C [10°F] or below for a minimum of one hour. Be ready to Install a sleeve immediately after removing it from the freezer.
Apply a coat of Loctite 620 to the bore that is to be sleeved.
Wear protective gloves. Push the cold sleeve into the bore as far as possible.
Using a sleeve driver, drive the sleeve downward until it contacts the step at the bottom of the bore.
Driver Construction
Driver - aluminum
Handle - steel
^ A = 1 27mm [5 inch]
^ B = 38mm [1.5 inch]
^ C = 6.35mm [0.250 inch]
^ D = 25.4mm [1.00 inch]
^ E = 101 mm [3.976 Inch]
^ F = 107.343mm [4.226 Inch]
Set up a boring bar and machine to the following dimensions.
^ A = 101.956mm [4.014 inch]
^ B = Minimum - flush with block Maximum - 0.05 mm [0.0019 inch] protrusion
After removing the boring bar, use a honing stone to chamfer the corner of the repair sleeve(s) to dimension C.
^ C = Approximately 1.25 mm [.049 inch] X 15 Degrees
A correctly honed surface will have a cross-hatch appearance with the lines at 15 to 25 degree angles with the top of the cylinder block.
^ Rough hone: use 60 grit honing stones.
^ Finish hone: use 280 grit honing stones.
Finished bore inside dimension: 102.020 +/- 0.020 mm [4.0165 +/- 0.0008 inch]
A maximum of 1.2 micrometer [48 microinch] surface finish must be obtained.
After finish honing is complete:
^ Immediately clean the cylinder bores with a strong solution of laundry detergent and hot water.
^ After rinsing, blow the block dry with compressed air.
Wipe the bore with a white, lint-free, lightly oiled cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will not be used right away.