Cylinder Block Assembly: Service and Repair
CYLINDER BORE HONINGBefore honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
1. Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required limits.
CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylinder surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60 strokes, depending on the bore condition, will be sufficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors.
CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 69).
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up and down strokes increase the crosshatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lint free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.
CLEANING
CAUTION: Remove all gasket material from cylinder block using a plastic gasket scraper and Mopar(r) Brake Parts Cleaner or the equivalent, this will prevent damage to the cylinder block.
1. When cleaning the cylinder block, remove the oil gallery plugs at the front and rear of the block.
2. Remove coolant core plugs on sides of the block.
3. Spray compressed air into all oil gallery passages to ensure they are clear of blockage.
4. Use a wooden or plastic scraper and Mopar Brake Parts Cleaner or the equivalent to remove the old gasket.
5. Use fine grade Scotch Brite or equivalent to remove any small amounts of gasket material.
6. Clean the oil passages in the crankshaft with a brush.
INSPECTION
The cylinder walls should be checked for out-of-round and taper with Special Tool C-119 (Fig. 70). If the cylinder walls are badly scuffed or scored, the cylinder bore can be machined oversize. Oversize piston and rings are available.
Measure the cylinder bore at three levels in directions A and B (Fig. 70). Top measurement should be 12 mm (0.50 inch) down and bottom measurement should be 12 mm (0.50 inch) up from bottom of bore.