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REPAIR INSTRUCTIONS
Page 137
INSPECTION
A complete discussion of the proper methods of
precision measuring and inspection is outside the
scope of this manual. However, every shop
should be equipped with standard gauges, such
as bore gauges, dial indicators, outside and
inside micrometers, thickness gauges and
straightedges.
Check the cylinder block for indications of
cracking or coolant leakage. If any damage is
suspected, use a standard dye penetrant or
magnaflux procedure to determine if cracks exist.
A cracked engine block must be replaced and
never reused.
Refer to Figure 127.
Using a straightedge (PT5027 or equivalent) and
thickness gauges, check the cylinder head
mounting surfaces for flatness. The cylinder block
mounting surface on a service block should be
flat within 0.004 inch (0.102 mm).
127
Figure 127 — Checking Flatness of Cylinder Block Deck
If the cylinder block is determined to be
serviceable after thorough cleaning and
inspection, reassemble the engine. Use
replacement or original parts, as determined
during component inspection.
Cylinder Sleeve Counterbore
[211 DB]
INSPECTION AND REPAIR
If the cylinder block deck is resurfaced, the
cylinder sleeve counterbore depth must be recut
to specification. If the cylinder block deck was not
resurfaced but cylinder sleeve counterbore
surface shows excessive pitting or erosion, recut
the counterbore as required.
Use shims to re-establish the correct liner flange
height. Shims are available in the following
thicknesses: 0.002, 0.003, 0.004, 0.008, 0.010,
0.012 and 0.014 inch.
To resurface the cylinder sleeve counterbore area
of the cylinder block, use counterbore tool
PT2210 with counterbore cutter plate PT2210-3A.
This procedure can be performed either in or out
of the chassis. If performing the procedure in the
chassis, be sure to cover the crankshaft and any
holes in the block to prevent contamination from
machining chips.
Do not cut seats deeper than 4.034 inches
(102.464 mm).
1. Make sure that the top of the deck is clean
and free of burrs. Use a finish mill file and
crocus cloth, if necessary, to create a
smooth, flat surface for positioning the tool.
2. Using compressed air, thoroughly remove all
debris.
Universal dial depth gauge PT5025, with a three-
inch stylus extension PT5052-11, is
recommended for measuring the counterbore.
5_106_00.bk Page 137 Friday, August 4, 2000 11:17 AM
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