5. Cylinder Block Inspection
- Tools Required
- SA9177E Straight Edge
- SA9llOlNE Feeler Gauge Set
- SA9179NE Dial Indicator
- SA9187NE Ridge Reamer
1. Remove gasket material.
Using a gasket scraper, Scotch Brite Pads and Disk (EMU Clean' N Strip 2 inch D x 1/2 inch W x 1/4 inch center hole) remove all the gasket material from the cylinder block, oil pan, rear seal carrier, and front cover surfaces.
a. The oil pan, front cover, and rear seal carrier bolt holes in cylinder block will require cleaning with a 4.76 mm (3/16 inch) drill and tap handle to remove RTV.
IMPORTANT: If excessive RTV (wet or dry) accumulates in blind holes, the casting will crack when bolts are installed.
b. When all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol Saturn P/N 21007432 (or equivalent).
IMPORTANT: Do not use petroleum cleaners such as mineral spirits; they leave a film onto which RTV will not stick.
c. If cylinder block oil gallery plugs are removed, clean the threads and apply Saturn P/N 21485276 (Loctite 290 or equivalent). Do not over-torque the plugs.
Torque: 30 Nm (22 ft. lbs.)
2. Clean the cylinder block:
NOTICE: Use extreme care and do not damage or scratch the machined aluminum surfaces and the cylinder bores. Do not heat the cylinder block above 44° C (120° F).
Using a soft scrub brush and solvent, clean the entire block of oil, debris, etc.
3. Inspect top of cylinder block for flatness:
a. Using a precision straight edge SA 9177NE (or equivalent) and feeler gauge SA 91101NE (or equivalent), measure the surfaces contacting the cylinder head gasket for warpage.
Transverse Warpage:
Standard: 0.024 mm (0.0009 inch) max.
Service Limit: 0.05 mm (0.0020 inch) max.
Longitudinal Warpage:
Standard: 0.080 mm (0.0031 inch) max.
Service Limit: 0.10 mm (0.0040 inch) max.
If warpage is greater than maximum, replace the cylinder block.
4. Inspect cylinders for scoring or vertical scratches:
If deep scratches are present, hone or bore the worn or scored cylinders. Refer to "Cylinder Honing and Boring".
5. Inspect cylinder bore diameter:
Using a cylinder bore gauge, measure the cylinder bore diameter at positions A, B, and C in the transverse and longitudinal directions. Record these dimensions.
Calculate the average diameter at each position (A, B, and C). The average value is the dimension to be compared to specifications.
Standard Diameter:
Cylinder Bore Diameter No. 2 and 3:
Standard: 81.99 - 82.01 mm (3.2280 - 3.2287 inch)
Service Limit: 82.035 mm (3.2297 inch) max.
(average X and Y direction measurements)
Cylinder Bore Diameter No. 1 and 4:
Standard: 82.00 - 82.02 mm (3.2283 - 3.2291 inch)
Service Limit: 82.045 mm (3.2301 inch) max.
(average X and Y direction measurements)
Cylinder Bore Taper:
Standard: 0.010 mm (0.0004 inch) max.
Service Limit: 0.050 mm (0.0020 inch) max.
(average X and Y direction measurements)
Use the cylinder bore taper calculation chart to calculate bore taper.
If the diameter is greater than maximum, hone, or re-bore the worn or scored cylinders. If necessary, replace the cylinder block.
6. Using a sled gauge SA 9179NE (or equivalent) (dial indicator mounted on a steel block) or straight edge and feeler gauge, measure the cylinder liner height at position A, B, C, and D at the top of the cylinder block.
Liner Height Above or Below Cylinder Block:
Standard: Flush
Service Limit: 0.013 mm (0.0005 inch) max.
If the liner height is below the cylinder block, the cylinder block may require surfacing or replacement.
Top side of main bearing bore to cylinder head deck surface:
Service Limit: 189.26 mm (7.4511 inch) min.
7. Remove cylinder ridge reamer SA 9187NE (or equivalent), if not previously completed during piston removal.
If a ridge can be felt in the cylinder bore above the upper ring, use a ridge reamer to machine the piston ring ridge at the top of the cylinder.
IMPORTANT: Failure to remove a ridge can cause upper piston ring damage when new rings are installed.