Cleaning Procedure
- Clean all gasket surfaces, the oil passages, the coolant passages and the engine block with solvent.
- Clean all threaded holes with solvent. Be sure to remove any old thread sealant material.
- Prior to the application of RTV sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the engine block seal groove clean the groove and mating surfaces of the upper engine block and the mating surface of the
lower crankcase with cleaner solvent GM P/N 12378392 or 12346139 (Canadian P/N 88901247).
Visual Inspection Procedure
- Inspect all threaded holes for damage or excessive debris.
- Inspect the cylinder block for cracks in the cylinder walls, the coolant jackets and the crankshaft bearing webs.
- If cracks are found, the cylinder block must be replaced.
Cylinder Bore Diameter Measurement Procedure
- Measure the cylinder bore diameter at 41 mm (1.61 in) below the cylinder block deck surface.
- Compare your results with the engine mechanical specifications. If the cylinder diameter exceeds the specifications, the cylinder block must be replaced. There are no oversized pistons available for service.
Deck Face Flatness Measurement Procedure
- Place a straight edge across the deck face of the cylinder block at an angle starting at the front of the block and sloping downward to the rear of the block.
- Measure the gap between the straight edge and cylinder block by sliding the feeler gauges under the straight edge at the front, center and rear of the block. Insert the greatest thickness gauge that will fit.
- Find the difference between the largest and smallest measurement.
- Change the position of the straight edge so that the angle travels up from the front of the block to the rear.
- Measure the gap between the straight edge and the deck face again at the front, center and rear. Insert the greatest thickness gauge that will fit.
- Find the difference between the largest and smallest measurement.
- Position the straight edge so it travels through the center of the cylinder bores.
- Measure the gap between the straight edge and the deck face a final time at the front, center and rear. Insert the greatest thickness gauge that will fit.
- Find the difference between the largest and smallest measurement.
- Compare your measurement to the engine mechanical specifications.
Important: If the flatness measurement exceeds the specifications, replace the cylinder block. Machining of the deck face surface is NOT allowed.
Cylinder Bore Taper Measurement Procedure
- Measure the cylinder bore along the thrust surfaces (perpendicular to the crankshaft centerline) at 5 mm (0.20 in) below the deck surface and record your measurement.
- Measure the cylinder bore along the thrust surfaces (perpendicular to the crankshaft centerline) at 102 mm (4.00 in) below the deck surface and record your measurement.
- Calculate the difference between the two measurements. The result will be the cylinder taper.
- Compare your results with the engine mechanical specifications. If the cylinders exceed these specifications, replace the cylinder block.
Cylinder Bore Out-of-Round Measurement Procedure
- Measure both the thrust and non-thrust cylinder diameter 5 mm (0.20 in) below the deck surface. Record your measurements.
- Calculate the difference between the two measurements. The result will indicate out-of-round at the upper end of the cylinder.
- Measure both the thrust and non-thrust cylinder diameter 102 mm (4.00 in) below the deck surface. Record your measurements.
- Calculate the difference between the two measurements. The result will indicate out-of-round at the lower end of the cylinder.
- Compare your results with the engine mechanical specifications. If the cylinders exceed these specifications, replace the cylinder block.