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REPAIR INSTRUCTIONS, PART 1
Cylinder Block Cleaning and
Inspection
The engine should have been thoroughly steam
cleaned prior to component removal. If heavy
accumulations of dirt and grease are still present,
steam clean the cylinder block as thoroughly as
possible before attempting to clean with solvents.
Cleaning solvent is flammable and toxic to the
eyes, skin and respiratory tract. Skin and eye
protection is required. Avoid repeated or
prolonged contact. Use only in a
well-ventilated area. Failure to heed this
warning may result in severe personal injury.
Compressed air used for cleaning can create
airborne particles that may enter the eyes or
irritate the skin. Pressure must not exceed
207 kPa (30 psi). Eye protection is required.
Use only with effective chip guarding and
personal protective equipment
(goggles/shield, gloves, etc.). Failure to heed
this warning may result in severe personal
injury.
Cleaning the cylinder block is important. While
cleaning the cylinder block, carefully inspect the
areas around the cup plugs and the cooling duct
cover. If cup plugs or pipe plugs show signs of
leaking, they should be replaced.
Cleaning the cylinder block is a good time to
inspect it for cracks or other possible defects that
are reason for replacement. Refer to the
TROUBLESHOOTING section for information on
testing for leaks in the cylinder head and cylinder
block. If damage is not found until after the engine
is assembled, the engine must be disassembled
and rebuilt again.
SOLVENT TANK CLEANING
Use a cleaning tank large enough to
accommodate the largest component to be
cleaned. Fill the tank with a suitable solvent.
Parts may be dried with compressed air.
Always use caution while cleaning parts with
solvents. Failure to heed this warning may
result in personal injury.
1. Scrape any remaining gasket material from
the cylinder block.
2. Using a wire brush or rotary wheel, remove
any rust, corrosion or other debris from the
cylinder block.
3. Clean all other cylinder block surfaces with
mineral spirits or other suitable solvent.
4. Using due care and caution, clean and dry
the cylinder block with compressed air.
INSPECTION
A complete discussion of the proper methods for
precision measuring and inspection is outside the
scope of this procedure. 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 to
determine if cracks exist. A cracked cylinder block
must be replaced and never reused.
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