Cleaning and Inspection of Cylinder Block

(a)

Remove all carbon, dirt, and oil from

block. Check the depth of the flange counterbores in the

block to be sure the specified sleeve protrusion above

cylinder sleeves and machine recess bore in cylinder

the top deck of the block is maintained.

block. Replace cylinder sleeves if scored or worn

2. Install the dry silicone cylinder

beyond allowable limits of 0.008 inch. Slightly scuffed

sleeve packing rings in both grooves in the cylinder

cylinder sleeves, if not worn, may sometimes be made

block. 3. Brush a light coat of light engine lubricating oil

usable by polishing or lapping to remove surface

in the lower sleeve bores and on the sleeve rubbers in

irregularities.

(b)

Check cylinder sleeves for roundness by

the cylinder block and on the sleeve immediately prior to

installation of the sleeve in the cylinder block.

means of a cylinder diameter checking gauge. Allowable

CAUTION

out-of-round when installed is 0.001 inch. Using an

inside micrometer, measure cylinder sleeve for taper and

Use only a light engine lubricating oil

wear. Inside diameter of new cylinder sleeve is 3.4379

as a lubricant for the cylinder sleeve

inch to 3.4385 inch. Cylinder sleeve should be round to

packing

rings

when

installing

within 0.001 inch, and have no more than 0.0007-inch

cylinder sleeves in a cylinder block.

taper. Cylinder sleeves that are more that 0.001 inch

(d) With silicone rubber seal rings installed,

out- of-round or have more than 0.0007-inch taper when

install sleeve in position in cylinder block, being careful

installed, must be replaced.

These measurements

not to cut or scratch seal rings. When sleeve is nearly in

should be taken at several locations within the area of

place, apply pressure to opposite sides of sleeve with

piston ring travel.

hands and press into place with a sudden, quick

application of pressure. Be careful not to get dirt under

allowable wear limits and are to be used again, there

flange of sleeve, which would prevent it from properly

may be a slight ring travel ridge near top of the sleeve

seating.

which should be removed with a ridge reamer. Follow

(e) With flange of cylinder sleeve firmly

the instructions of the manufacturer of the specific ridge

seated in counterbore of cylinder block, top surface of

reamer.

cylinder sleeve must be -0.002 inch to +0.002 inch above

(d) Refer to paragraph 3-22 for

top flat surface of the cylinder block. Hold a straightedge

instructions on the fitting of pistons in cylinder sleeves.

across cylinder sleeve and use a feeler gauge to

(5) Installation of cylinder sleeve.

measure standout of sleeve flange above block.

(a) Thoroughly clean cylinder sleeve (2,

c. Cleaning and Inspection of Cylinder Block. The

fig. 3-32) and the bore in cylinder blocks (3). Be sure

cylinder block is the main structural part of the engine,

bottom surface of flange on cylinder sleeve and

therefore, whenever engine is overhauled, thoroughly

counterbore in cylinder block are clean and free from

inspect block for any damage which may render it unfit

nicks or burs.

for further use. Make inspection of block after all parts

(b) Before installing silicone rubber seal

have been removed and it has been thoroughly cleaned

rings (1) insert sleeve (2) into bore to make certain

with steam or cleaning solvent (Spec P-S-661) and dried

sleeve can be pushed down into place by hand pressure.

with compressed air. All oil passages in cylinder block

Withdraw sleeve from block. If sleeve cannot be

must be cleaned before assembling engine. Effective

inserted in above manner, more cleaning is necessary or

cleaning of these passages can be accomplished only

sleeves are distorted.

with the use of high steam pressure with a solvent used

in the water to dissolve the sludge and foreign material

follows:

that has collected. Open all passages before flushing.

1. Thoroughly clean the cylinder

(1) Remove expansion plugs (4, fig. 3-32) at

sleeves and wipe or blow them dry. Thoroughly clean

front and rear of engine.

the sleeve bores and O-ring grooves in the cylinder

block. Check the sleeve flange counterbores in the

block to be sure the sleeve flange seats are true and

square with the upper and lower deck sleeve bores in the

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