Tools Required

1. Remove any old thread sealant, gasket material or sealant using J 28410 .
2. Clean all the following areas with solvent:

•	Sealing surfaces

•	Cooling passages

•	Oil passages

•	Bearing journals

3. Clean all threaded and through holes with solvent.

Caution: Refer to Safety Glasses Caution in the Preface section.

4. Dry the cylinder block with compressed air.

1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the cylinder block assembly must be replaced.
2. Inspect the primary camshaft drive chain tensioner mounting surface on the cylinder block for burrs or any defects that may degrade the sealing of the NEW primary camshaft drive chain tensioner gasket.
3. Inspect all sealing and mating surfaces for damage, repair or replace the cylinder block assembly if necessary.
4. Inspect all threaded and through holes for damage or debris above acceptable tolerances.
5. Inspect all bolts for damage, if damaged replace with NEW bolts only.
6. Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the cylinders are damaged the cylinder block assembly must be replaced.
7. Inspect the cylinder block for cracks. DO NOT repair any cracks. If cracks are found, the cylinder block assembly must be replaced.
8. Repair any damaged threaded holes. Refer to Thread Repair Specifications and Thread Repair .

1. Measure the cylinder bore diameter 42 mm (1.654 in) from the deck face (1) using the J 8087  (2).
2. Record and 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.

If the cylinder bore exceeds specification by more than 0.25 mm (0.010 in) the cylinder block must be replaced.

1. 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.
2. 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.
3. Calculate the difference between the 2 measurements. The result will be the cylinder taper.
4. 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.

If the cylinder bore exceeds specification by more than 0.25 mm (0.010 in) the cylinder block must be replaced.

1. Measure both the thrust and non-thrust cylinder diameter at 10 mm (0.397 in) below the deck. Record your measurements.
2. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the upper end of the cylinder.
3. Measure both the thrust and non-thrust cylinder diameter at 100 mm (3.976 in) below the deck surface. Record your measurements.
4. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the lower end of the cylinder.
5. 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.

If the cylinder bore exceeds specification by more than 0.25 mm (0.010 in) the cylinder block must be replaced.

1. Make sure the cylinder block decks are clean and free of gasket material.
2. Inspect the surface for any imperfections or scratches that may inhibit correct cylinder head gasket sealing.
3. Place a straight-edge diagonally across the cylinder block deck face surface.
4. Measure the clearance between the straight-edge and the cylinder block deck face using a feeler gauge at 4 points along the straight-edge.
5. If the warpage is less than 0.05 mm (0.002 in), the cylinder block deck surface does not require resurfacing.
6. If the warpage is between 0.05-0.20 mm (0.002-0.008 in) or any imperfections or scratches that may inhibit correct cylinder head gasket sealing are present, the cylinder block deck surface requires resurfacing.
7. If resurfacing is required the maximum amount that can be removed is 0.25 mm (0.010 in).
8. If the cylinder block deck surface requires more than 0.25 mm (0.010 in) material removal the block must be replaced.