Block inspection
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Block inspection. Some visual checks Cylinder cracking. Scuffing & scoring. Damaged fasteners. Housing bores. Copyright 2003 Gary Lewis – Dave Capitolo. Block inspection. Crack detection Bolt holes. Main bearing webs. Core plug holes. Intake valley. Block inspection.

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Block inspection

  • Some visual checks

    • Cylinder cracking

  • Scuffing & scoring

  • Damaged fasteners

  • Housing bores

Copyright 2003 Gary Lewis – Dave Capitolo


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Block inspection

  • Crack detection

    • Bolt holes

  • Main bearing webs

  • Core plug holes

  • Intake valley


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Block inspection

  • Cylinder wear

    • Maximum wear 90 across piston pin, at top of cyl

  • Head bolts & coolant circulation distort cylinder

  • Taper – difference between bottom and most worn

  • Actual wear exceeds measured

  • Taper limit - .008”


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Block inspection

  • Piston clearance

    • Don’t confuse taper with clearance

  • Minimum cylinder diameter – max piston diameter


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Block inspection

  • Checking pistons

    • Ring groove wear = .003” to .006” or 2 times new


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Block inspection

  • Checking pistons

    • Worn or collapsed piston skirts

  • Measure 90º across piston pin at top & bottom

  • Knurling – If clearance exceeds specs up to .002”


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Block inspection

  • Checking pistons

    • Collapsed piston – When piston loses cam shape

  • Measure 45º across piston pin

  • Leads to piston ‘slap’


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Block inspection

  • Checking piston pin clearance

    • Oscillating pins are checked by feel

  • Full floating pins can be disassembled & measured

  • .0002” clearance in pistons

  • .0004” clearance in rods


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Block inspection

  • Checking block flatness

    • Scrape deck surface

  • Deburr deck surface

  • .004” Go/No-go

  • Consider head flatness


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Block inspection

  • Measuring main housing bores

    • Main caps stretch from load

  • Check block for warpage


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Block inspection

  • Measuring main housing bores

    • Check bearing wear

  • Bent crankshaft – Wear all around bearing

  • Warped crankcase – Wear on one side only

  • Concentricity of main seal


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Block inspection

  • Measuring main housing bores

    • Clean & deburr parting faces

  • Check fit in saddle

  • Torque & measure with dial bore gauge


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Block inspection

  • Checking the crankshaft

    • Scoring

  • Taper & out of round

  • Taper exceeding .0005” may allow oil to escape


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Block inspection

  • Crankshaft straightness

    • Use V-blocks or end main bearings

  • Should not exceed ½ main clearance


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Block inspection

  • Crankshaft cracks

    • “Ring” crankshaft

  • Wet Magnaflux crankshaft


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Block inspection

  • Connecting rod bores

    • Stretch comes from engine load

  • High engine speeds tend to stretch bores

  • Small displacement engines use large rod bores

  • Caps may spring outward on disassembly

  • Bend & twist should be within .001” per 6” of rod.

  • Cause wear patterns on pistons & bearings


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Block inspection

  • Connecting rod bores

    • Special gauges are used for housing bores

  • Out of round & size must be checked


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Block inspection

  • Connecting rod failures

    • Begin with bearing failure

  • Bearing shell wedges under the other

  • Rod bolt breaks

  • Rod & cap break


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