Cylinder Block Assembly: Service and Repair

STANDARD PROCEDURE-CYLINDER BLOCK REFACING





1. The combustion deck can be refaced twice. The first reface should be 0.25 mm (0.0098 inch). If additional refacing is required, an additional 0.25 mm (0.0098 inch) can be removed. Total allowed refacing is 0.50 mm (0.0197 inch) - (Fig. 68).





2. The upper right corner of the rear face of the block must be stamped with a X when the block is refaced to 0.25 mm (0.0098 inch). A second X must be stamped beside the first when the block is refaced to 0.50 mm (0.0197 inch) - (Fig. 69).
3. Consult the parts catalog for the proper head gaskets which must be used with refaced blocks to ensure proper piston-to-valve clearance.

STANDARD PROCEDURE-CYLINDER BORE BE-GLAZE
1. New piston rings may not seat in glazed cylinder bores.
2. De-glazing gives the bore the correct surface finish required to seat the rings. The size of the bore is not changed by proper de-glazing.
3. Cover the lube holes in the top of the block with waterproof tape.





4. A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles (Fig. 70). For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
5. Use a drill, a fine grit Flex-hone and a mixture of equal parts of mineral spirits and SAE 30W engine oil to de-glaze the bores.





6. The crosshatch angle is a function of drill speed and how fast the hone is moved vertically (Fig. 71).
7. Vertical strokes MUST be smooth continuous passes along the full length of the bore (Fig. 71).
8. Inspect the bore after 10 strokes.
9. Use a strong solution of hot water and laundry detergent to clean the bores. Clean the cylinder bores immediately after de-glazing.
10. Rinse the bores until the detergent is removed and blow the block dry with compressed air.
11. Check the bore cleanliness by wiping with a white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all residue is removed. Wash the bores and the complete block assembly with solvent and dry with compressed air.
12. Be sure to remove the tape covering the lube holes after the cleaning process is complete.

STANDARD PROCEDURE-CYLINDER BORE REPAIR
Cylinder bore(s) can be repaired by one of 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.

METHOD 1-OVERSIZE BORE
Cylinder bore(s) can be repaired by one of two methods:
Oversize pistons and rings are available in two sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393 inch).
Any combination of standard, 0.50 mm (0.0197 inch) or 1.00 mm (0.0393 inch) overbore may be used in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is needed, a repair sleeve can be installed (refer to Method 2-Repair Sleeve).





Cylinder block bores may be bored twice before use of a repair sleeve is required (Fig. 72). The first bore is 0.50 mm (0.0197 inch) oversize. The second bore i: 1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer the edge of the bore (Fig. 72).





CYLINDER BORE DIMENSION CHART





A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the cylinder block (Fig. 73). For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
A maximum of 1.2 micrometer (48 microinches) 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.

METHOD 2-REPAIR SLEEVE
If more than a 1.00 mm (0.03937 inch) diameter oversize bore is required, the block must be bored and a repair sleeve installed.





Bore the block cylinder bore to 104.500 - 104.515 mm (4.1142 - 4.1148 inch) - (Fig. 74).
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.





REPAIR SLEEVE BLOCK REBORE DIMENSIONS CHART

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 the sleeve immediately after removing it from the freezer.
Apply a coat of Loctite 620, or equivalent to the bore that is to be sleeved.
Wear protective gloves to 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 (Fig. 75).





A sleeve driver can be constructed as follows (Fig. 76).





SLEEVE DRIVER CONSTRUCTION SPECIFICATION CHART





Set up a boring bar and machine the sleeve to 101.956 mm (4.014 inch) - (Fig. 77).
After removing the boring bar, use a honing stone to chamfer the corner of the repair sleeve(s) - (Fig. 77).





SLEEVE MACHINING DIMENSIONS CHART

A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
Finished bore inside dimension is 102.020 ± 0.020 mm (4.0165 ± 0.0008 inch).
A maximum of 1.2 micrometer (48 microinches) 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 immediately.
A standard diameter piston and a piston ring set must be used with a sleeved cylinder bore.

STANDARD PROCEDURE-CAM BORE REPAIR
The front cam bushing bore can be bored to 59.235 mm ± 0.013 mm (2.332 inch ± 0.0006 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 bored to 57.235 mm ± 0.013 mm (2.253 inch ± 0.0006 inch) oversize.
A surface finish of 2.3 micrometers (92 microinches) must be maintained. Not more than 20% of an area of any one bore may be 3.2 micrometers (126 microinches).
Camshaft bores can be repaired individually. It is not necessary to repair undamaged cam bores in order to repair individually damaged cam bores. The standard front bushing cannot be used to repair intermediate or rear 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 (Fig. 78).

INSPECTION





Measure the combustion deck face using a straight edge and a feeler gauge (Fig. 79). The distortion of the combustion deck face is not to exceed 0.010 mm (0.0004 inch) in any 50.00 mm (2.0 inch) diameter. Overall variation end to end or side to side is 0.075 mm (0.003 inch).
If the surface exceeds the limit,.
Inspect the cylinder bores for damage or excessive wear.





Measure the cylinder bores (Fig. 80). If the cylinder bores exceeds the limit, Refer to ENGINE BLOCK - STANDARD PROCEDURE.
Inspect the camshaft bores for scoring or excessive wear.
Measure the camshaft bores Limit for the No.1 bore applies to the ID of the bushing.
If a bore exceeds the limit, Refer to CAMSHAFT & BEARINGS (IN BLOCK).





Inspect the tappet bores for scoring or excessive wear 16.000 mm min - 16.055 mm max (0.63 in. mm - 0.6321 in. max ) (Fig. 81). If out of limits, replace the cylinder block.