Engine Block Cleaning and Inspection
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Engine Block Cleaning and Inspection
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Measure the cylinder bore diameter 37 mm (1.457 in) from the deck face using the
EN 8087
gauge.
Compare your results with the
Engine Mechanical Specifications
. 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.
Measuring Cylinder Bore Taper
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1.
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Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 10 mm (0.397 in) below the deck surface and record your measurement.
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2.
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Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 100 mm (3.976 in) below the deck surface and record your measurement.
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3.
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Calculate the difference between the 2 measurements. The result will be the cylinder taper.
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4.
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Compare your results with the
Engine Mechanical Specifications
. 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.
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Measuring Cylinder Bore Out-of-Round
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1.
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Measure both the thrust and non-thrust cylinder diameter at 10 mm (0.397 in) below the deck. Record your measurements.
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2.
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Calculate the difference between the 2 measurements. The result will indicate out-of-round at the upper end of the cylinder.
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3.
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Measure both the thrust and non-thrust cylinder diameter at 100 mm (3.976 in) below the deck surface. Record your measurements.
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4.
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Calculate the difference between the 2 measurements. The result will indicate out-of-round at the lower end of the cylinder.
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5.
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Compare your results with the
Engine Mechanical Specifications
. 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.
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1.
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Ensure the engine block decks are clean and free of gasket material.
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2.
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Inspect the surface for any imperfections or scratches that could inhibit proper cylinder head gasket sealing.
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3.
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Place a straight-edge diagonally across the cylinder block deck face surface.
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4.
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Measure the clearance between the straight-edge and the cylinder block deck face using a feeler gauge at 4 points along the straight-edge.
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5.
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If the warpage is less than 0.05 mm (0.002 in), the cylinder block deck surface does not require resurfacing.
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6.
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If the warpage is between 0.05-0.20 mm (0.002-0.008 in) or any imperfections or scratches that could inhibit proper cylinder head gasket sealing are present, the cylinder block deck surface requires resurfacing.
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7.
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If resurfacing is required the maximum amount that can be removed is 0.25 mm (0.010 in).
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8.
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If the cylinder block deck surface requires more than 0.25 mm (0.010 in) material removal the block must be replaced.
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