You will need a solvent tank large enough to hold the larger engine parts, along with various bristle brushes and a gasket scraper. A source of compressed air will be helpful in the cleaning operations.

Precision measuring tools will be required for the inspection procedure. These include: micrometers, cylinder bore gage, feeler gage, dial indicators sets, etc. It is very important that the inspection work be performed with the proper methods and tools. The rebuilt engine cannot be expected to perform properly, if any of the parts are worn beyond their serviceable limits.

The cylinder block needs to be inspected thoroughly to determine if it is reusable. Before the cylinder block inspection can be performed, it should be stripped of all coolant plugs and oil gallery plugs. To prevent dirt from being stuck into the oil bypass valves, they must be removed before the cylinder block can be cleaned.

1. Remove the oil pipe.
2. Remove the oil filter assembly.
3. Remove the cup plugs and the block heater (if equipped).
4. Remove the oil gallery plugs (if equipped).

1. Place the block into the approved cleaning solvent.

Important: Use only the proper cleaning solvent when removing old gasket material.

2. Clean the old gasket material from the sealing surfaces.
3. Using compressed air, blow through all oil passages. Wear protective safety glasses and gloves.
4. Clean scale deposits from the coolant passages.
5. Clean the crankshaft.

1. Inspect the cylinder block for cracks and wear.
2. Inspect the coolant jackets.
3. Inspect the crankshaft bearing webs.
4. Inspect the engine mounting bosses.
5. Inspect the thrust washer mating surfaces on the cylinder block and lower crankcase.



6. Measure the cylinder block for warpage. Use a straight edge and a feeler gage to measure the four sides and the two diagonals of the cylinder block. If the measured values exceed the 0.2 mm (0.008 in), the cylinder block must be replaced.
7. Measure the crankshaft bearing bores (cylinder block and lower crankcase).
8. Use an inside micrometer and measure the crankshaft bearing inside diameter.

Subtract the crankshaft main bearing journal diameter from the crankshaft main bearing inside diameter to obtain the proper clearances

•	No. 4 crankshaft main bearing journal

-	Production: 0.093-0.124 mm (0.0037-0.0049 in)

-	Service Limit: 0.14 mm (0.0055 in)

•	All other crankshaft main bearing journals:

-	Production: 0.063-0.094 mm (0.0025-0.0037 in)

-	Service Limit: 0.14 mm (0.0055 in)