CBCAUTOMOTIVERKCBCAUTOMOTIVERK CHAPTER OBJECTIVES u Analyze wear and Damage to the Cylinder Block. u Select & Perform appropriate repairs. u R & R cam bearings, gallery plug, core plugs. u Explain theories of cylinder wall finishes.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK CHAPTER INTRODUCTION u Blocks can usually be reused. u All will need cam bearings, Soft plugs, and Cleaning. u Most will have cylinders bored oversize. u Some will need the Deck resurfaced. u A few will need Align Boring of the Main Bearings. Page 261
CBCAUTOMOTIVERKCBCAUTOMOTIVERK CLEANING THE BLOCK u The block must be thoroughly cleaned. u All core plugs, oil gallery plugs, BEARINGS, & other parts - u Must be removed before hot tanking. u Flush thoroughly to remove caustic solution from water jackets. u Lubricate bores - Check for cracks.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK INSPECTION u Measure cylinder bores for taper & out- of-round. u Measure decks for straightness. u Measure main journals for straightness. u Inspect all threads, DNR. u Magniflux for cracks.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK OIL AND WATER PLUGS u Oil galleries must be cleaned with a brush after tanking. u Pipe threads are tapered thread. u You can leave one end in place if necessary.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK DECKING THE BLOCK u Do not make surface to smooth. u Remove all nicks and burrs. u Blocks can be milled or ground to true deck surfaces.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK CHECKING THE DECK
CBCAUTOMOTIVERKCBCAUTOMOTIVERK PISTON CLEARANCE u Dana Recommends.0015” piston to wall clearance. u Clearance is built into piston. u Better to hone cylinder to each piston. u Can be checked with a feeler gauge, 90 to wrist pin. u Dial bore gauge is more accurate.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK CHAMFERING THE CYLINDER u The chamfer is removed during the boring process. u A chamfer is necessary to aid in ring installation. u Use a chamfering cone and a drill. u DO NOT USE A RIDGE REAMER.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK CYLINDER SLEEVES u A deeply scored, rusted or cracked cylinder can be sleeved u Crack can not extend to the top or bottom of the cylinder. u Dry sleeve has interference fit of.0005” per inch. u Sleeve may be driven or pressed in. u Sometimes a step is left at the bottom.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK MAIN BEARING CAPS u Cylinders are bored with Main caps torqued in place. u Main bearings are bored with caps torqued in place. u Main caps are NOT interchangeable. u Heavy-Duty or High Performance engines use 4 bolt caps.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK MAIN BORE ALIGNMENT u Heating and cooling cycles can cause block warpage. u.0010” feeler gauge and strait edge. u When a journal is blued the block must be align bored. u Align bore or align hone.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK LIFTER BORES u Lift bores must be clean to ensure they will spin. u Bores can be cleaned with a brake hone. u Check for oversize bores. u Oversize bores with standard lifters will cause low oil pressure.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK FINAL BLOCK PREPARATION u Chase head bolt holes before cleaning. u Clean the block with soap and HOT WATER. u Use eye protection, to blow out bolt holes. u If block is milled or decked, bolt holes may be chamfered.
CBCAUTOMOTIVERKCBCAUTOMOTIVERK INSTALL OIL GALLERY & CORE PLUGS u Oil gallery plug may be coated with sealer or Teflon tape. u Press in plugs are cross staked. u Clean core plug holes with sandpaper before installation. u Use a tool that is 1/8” smaller than inside diameter of plug. u Install just past the chamfer on block.