2-42 Change 1
2-16. CYLINDER BLOCK REPAIR (Contd)
a. Remove six protective dust caps (9) and all plugs (10) from cylinder block (1).
When steam cleaning, protective clothing must be used. Failure to
use protective clothing may result in serious injury.
b. Thoroughly steam clean cylinder block (1).
c. Run rods with brushes through all oil passages and repeat step b.
Compressed air used for cleaning purposes will not exceed 30 psi
(207 kPa). Use only with effective chip guarding and personnel
protective equipment (goggles/shield, gloves, etc.).
d. Blow all dirt and cleaning solution from capscrew holes and oil passages with compressed air.
e. Refer to para. 2-9 for additional cleaning instructions.
Coat all cylinder bores, lifter bores, and machined surfaces with OE/HDO.
g. Apply pipe sealing compound to six protective dust caps (9) and all plugs (10) and install in
cylinder block (1).
For general inspection instructions, refer to para. 2-10.
If cylinder block inspection indicates that cylinder block is
suitable for continued use, except for out-of-round, taper, or
minor nicks or scratches, it can be conditioned by honing or
boring. The cylinder block can then be fitted with a Hi-Limit or
oversized piston (refer to para. 2-45, table 2-4 or 2-5). The 6.5L
engines do not have Hi-Limit pistons.
Inspect all surfaces and general overall condition of the cylinder block (1).
Visually check the cylinder block (1) for pitting in cylinder walls (4) and lifter bores (2). Replace
engine if pitted or distorted.
Inspect the cylinder block (1) for cracks in cylinder walls (4), water jacket (5), lifter bores (2), and
main bearing webs (8). Replace engine if cracked.
Inspect main bearing caps (6) for cracks, scoring, or damage. Replace engine if any are cracked,
scored, or damaged.
Inspect main bearing cap bolts (7) for damage. Replace if damaged.
Inspect dowel pins (3) for damage. Replace if damaged.
Using a straightedge and feeler gauge, check flatness of cylinder head sealing surfaces on cylinder
block (1). Flatness on cylinder block (1) must not vary more than 0.002 in. (0.051 mm) in a distance
of 6 in. (15.2 mm) or more than 0.006 in. (0.152 mm) overall. Repair cylinder or replace engine if
flatness does not meet above specifications.
Perform step 7.1 for 1997 6.5L engines only.
Inspect piston oil nozzles (11) and bores (12) for damage. Replace piston oil nozzles (11) if damaged.