5_108.bk Page 127 Thursday, October 4, 2001 11:45 AM
REPAIR INSTRUCTIONS Solvent Tank Cleaning
159
Use a cleaning tank large enough to accommodate the largest component to be cleaned. Fill the tank with a suitable solvent and always use caution while cleaning parts. Parts may be dried with compressed air. 1. Scrape any remaining gasket material from the block. 2. Using a wire brush or rotary wheel, remove any rust, corrosion or other debris from the block.
Figure 159 — Checking Flatness of Cylinder Block Deck
3. Clean all other block surfaces with mineral spirits or other suitable solvent. 4. Using due care and caution, clean and dry the block with compressed air. Inspection
A complete discussion of the proper methods of precision measuring and inspection is outside the scope of this manual. 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 or magnaflux procedure to determine if cracks exist. A cracked engine block must be replaced and never reused. Refer to Figure 159. Using a straightedge (PT5027, or equivalent) and thickness gauges, check the cylinder head mounting surfaces for flatness. The cylinder block mounting surface, on a service block, should be flat within 0.002 inch (0.051 mm) per head mounting.
If the cylinder block is determined to be serviceable after thorough cleaning and inspection, reassemble the engine. Use replacement or original parts, as determined during component inspection.
CORE PLUG REPLACEMENT Removal Refer to Figure 160. 1. Using a hammer and punch, drive one edge of the plug inward. The plug should rotate causing the opposite edge to move outward. When the edge moves out far enough, grab it with a pair of pliers and pull it out.
If, after several taps with a hammer, the plug does not rotate and is being driven inward, stop tapping. Drill a hole approximately 1/8 inch (3.2 mm) in diameter in the center of the plug. Insert a sheet-metal screw in the hole. Leave enough of the screw protruding from the plug to allow a pry bar to be inserted under the head of the screw and pry the plug out.
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