Cylinder Block

Cleaning and Inspection

If the engine (6007) has been removed and disassembled, remove all core plugs and pipe plugs. Clean the cylinder block (6010) using solvent, preferably in a hot tank. Follow all safety and environmental precautions with regards to the solvents. Make sure all oil and dirt is cleaned from the cylinder block.

Make sure all oil passageways are clean. A rifle-cleaning brush is useful for this purpose.

Use a long-thin screwdriver to scrape the bottom of the water jackets through the openings in the top deck to make sure all scale and deposits are removed. Most engines have a "dead spot" at the back of the block where the coolant has to make a U-turn and drops any deposits. If the water jackets are not thoroughly cleaned, overheating will result.

Cylinder Block Distortion

Cylinder block distortion is rare because cylinder blocks are normalized after casting, but before machining, to relieve internal stresses from the casting process.

The most probable cause of cylinder block distortion would be extreme overheating which would probably be accompanied by other damage such as scored bearings or cylinder walls, warped cylinder heads (6049), and possible cylinder block cracks.

Cylinder Head Deck Flatness

1. Place a straightedge across the cylinder head deck in the six positions shown and measure any gaps between the straightedge and the deck with a feeler gauge. The deck should be flat within 0.076mm (0.003 inch) over 152mm (6 inches) and 0.152mm (0.006 inch) overall.

2. Resurface or replace cylinder block if necessary.

Main Bearing Bore Alignment

Main bearing bore misalignment may be suspected in cases of premature bearing wear if one bearing wears considerably more than the others or bearings wear cone-shaped.

If bearing misalignment is suspected, perform the following steps.

1. Acquire a gauge bar the same diameter as the crankshaft journals and that is straight within 0.076mm (0.003 inch).

2. Put a thin coating of Prussian Blue or similar dye on gauge bar.

3. Insert good bearings in block.

4. Insert gauge bar in bearings and rotate one turn.

5. Remove gauge bar.

6. NOTE: Bearings are not available with oversize outside diameters to allow line boring.

   Inspect bearings. Blue dye should be deposited evenly on all bearings. If dye appears on only one side or bottom of bearing or not at all, cylinder block is distorted and should be replaced.

Flywheel Housing Deck Flatness

A concern with the rear deck of the engine would be indicated by the following:

• Frequent replacement of pilot bearing and transmission input shaft bearing on manual transmissions vehicles. Also hard shifting into high (not overdrive) gear or jumping out of gear.
• Frequent replacement of torque converter seals, input shaft seals or bearings, or pump on an automatic transmission vehicle.

If cylinder block-to-transmission misalignment is suspected, perform the following steps:

1. With crankshaft (6303) installed and engine rear plate (7007) and flywheel (6375) removed, attach Dial Indicator with Bracketry TOOL-4201-C or equivalent to crankshaft. The dial indicator can be mounted by any method that holds that extension bar so it does not sag.

2. Position the dial indicator on the machined flange slightly in from the edge.

3. Zero the dial indicator.

4. Because the shape of the flange is irregular, lift the tip of the dial indicator off of the flange.

5. Rotate the crankshaft to the 12 o'clock position and release the dial indicator tip.

6. Take the reading.

7. Lift the pointer off the flange and rotate the crankshaft so the dial indicator is just on the flange on the right side of the engine.

8. Release the pointer and take the reading. The readings should vary less than plus 0.076mm (0.003 in.).

9. Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent to transmission input shaft (7017).

10. Position dial indicator on transmission flange just above and inside of hole for left transmission bolt.

11. Zero dial indicator.

12. Slowly rotate transmission input shaft and take readings from dial indicator at 12 o'clock position and just above right-most transmission-to-engine bolt hole.

13. Reading should not vary more than 0.076mm (0.003 inch).

Sand Holes or Porous Engine Castings — Service

Porosity or sand hole(s), which will cause oil seepage or leakage, can occur with modern casting processes. A complete inspection of engine and transmission (7003) should be made. If the leak is attributed to the porous condition of the cylinder block or sand hole(s), service can be made with Ford Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A(E). Do not service cracks with this material. Service with this must be confined to those cast iron engine component surfaces where the inner wall surface is not exposed to engine coolant pressure or oil pressure, for example:

• Cylinder block surfaces extending along the length of the cylinder block, upward from the oil pan rail to the cylinder water jacket, but not including machined areas.
• Lower rear face of the cylinder block.
• Intake manifold casting. Service is not recommended to the intake manifold exhaust crossover section, since temperatures can exceed the recommended temperature limit of 260°C (500°F).
• Cylinder front cover on engines using cast iron material.
• Cylinder head, along the valve cover gasket surface.

The following procedure should be used to service porous areas or sand holes in cast iron.

1. Clean surface to be serviced by grinding or rotary filing to a clean bright metal surface. Chamfer or undercut hole or porosity to a greater depth than rest of cleaned surface. Solid metal must surround hole. Openings larger than 6.35mm (1/4 inch) should not be serviced using Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A(E). Openings in excess of 6.35mm (1/4 inch) can be drilled, tapped and plugged using common tools. Clean service area thoroughly. Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A(E) will not stick to a dirty or oily surface.

2. Mix base and hardener as directed on container. Stir thoroughly until uniform.

3. Apply service mixture with a suitable clean tool (putty knife, wood spoon, etc.) forcing epoxy into hole or porosity.

4. Allow service mixture to harden. This can be accomplished by two methods. Heat-cure with a 250-watt lamp placed 254mm (10 inches) from serviced surface, or air-dry for 10-12 hours at temperatures above 10°C (50°F).

5. Sand or grind serviced area to blend with general contour of surrounding surface.

6. Paint the surface to match the rest of the cylinder block.