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CYLINDER BLOCK INSPECTION & CLEANING

Learn how to analyze wear and damage, perform repairs, and clean the cylinder block. Includes instructions for R&R cam bearings, gallery plug, core plugs, and explanations of cylinder wall finishes.

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CYLINDER BLOCK INSPECTION & CLEANING

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  1. CYLINDER BLOCK INSPECTION & CLEANING • Chapter 11 • Classroom Manual • Page 259 • Lab Manual • Page 269

  2. 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.

  3. 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. Page 261

  4. 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.

  5. 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.

  6. 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.

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

  8. CHECKING THE DECK

  9. 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 wristpin. • Dial bore gauge is more accurate.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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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