Tools Required

1. Clean the sealing material from the gasket mating surfaces.
2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to Thread Repair .




Important: Do not attempt to machine the lower crankcase to engine block surfaces.

8. Use a straight edge and a feeler gage to check the deck surface for flatness. Refer to Engine Mechanical Specifications . If the deck surface is out of specification, replace the block. Do not machine the block.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.



10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side.



11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side.



12. Inspect the mating surfaces of the transmission face.

Notice: A broken flywheel may result if the transmission case mating surface is not flat.

13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses:

13.1.

Temporarily install the upper bearings, crankshaft and bedplate. Measure the crankshaft flange runout using the J 7872 .

13.2.

Hold the gage plate flat against the crankshaft flange.

13.3.

Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.

13.4.

Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in).

13.5.

Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).

14. Remove the bedplate.
15. Remove the crankshaft and bearings.
16. Install the bedplate.



17. Inspect the crankshaft main bearing bores. Use the J 8087 to measure the bearing bore concentricity and alignment.
18. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.



19. Inspect the cylinder bores using the J 8087 . Inspect for the following items:

•

Wear

•

Taper

•

Runout

•

Ridging

20. Refer to Engine Mechanical Specifications .
21. If the cylinder bores are out of specification, install a NEW cylinder bore sleeve. Refer to Cylinder Sleeve Removal and Cylinder Sleeve Installation .