CYLINDER BLOCK REPAIR - CONTINUED
INSPECTION - CONTINUED
Visually inspect bottom of counterbore for surface smoothness and signs of erosion. If surface is not completely smooth
or erosion is evident, proceed to step 32. If preliminary counterbore is satisfactory, proceed to step 36.
32. Use gage to set counterbore tool group for a depth of 0.104 in. (2.6416 mm).
33. Use counterbore tool group to make second counterbore.
34. Visually inspect bottom of counterbore for surface smoothness and signs of erosion. If surface is not completely smooth
or erosion is evident, proceed to step 35. If surface is completely smooth and free of erosion, proceed to step 36.
35. Measure depth of second counterbore. If depth exceeds 0.104+0.001 in. (2.6416+0.0254 mm), discard cylinder block. If
depth is satisfactory, proceed to step 36. If depth does not exceed 0.104+0.001 in. (2.6416+0.0254 mm), return to step
36. Use oiled crocus cloth and flat file, if necessary to remove burrs and sharp edges from finished counterbore and restore
surface to smooth, flat finish.
Measure and record exact depth at four places around each counterbore. Apply equal finger pressure on base of
micrometer for each measurement. Locate micrometer rod as close as possible to radius.
Remove inserts only if inspection indicates replacement is necessary.
Inserts are installed in counterbore with a slip (loose) fit. Top of insert is to project above top surface of
cylinder block from 0.002 to 0.006 in. (0.0508 to 0.1524 mm) Inserts installed next to each other cannot
differ in height more than 0.002 in. Inserts are variable in height so that proper combination of inserts
can be used to meet height specifications.
Determine exact height of each new insert (44), if removed, needed in each counterbore. Use insert (44) for 0.060 in.
(1.524 mm) counterbore and insert for 0.104 in. (2.6416 mm) counterbore. Inserts (44) can project over block 0.002 to
0.008 in. (0.0508 to 0.2032 mm), but inserts (44) adjacent to each other must be within 0.002 in. (0.0508 mm).
Use measurements taken in steps 1 and 2 to select new inserts, if removed, for proper placement in counterbore.
If only one insert is installed, coat both faces with gasket forming silicone compound. If more than one insert
is used, place thinnest insert on bottom and apply compound to only bottom face of bottom insert and top
face of top insert.
Install new inserts (44), if removed.