Cylinder block
Cleaning
1. Remove all external components and electrical sensors from the cylinder block, and also remove the generator and power steering pump brackets (see Figure 14.1, a-c).
Figure 14.1,a. Removing the oil pressure sensor from the cylinder block.
Figure 14.1.6. Removing the lower bracket of the power steering pump.
Figure 14.1, c. Generator adjustment bracket on the right side of the cylinder block.
2. For complete cleaning, ideally you need to remove the technological plugs from the cylinder block. To remove them, drill a small hole, then screw in a screw and remove the plug using pliers or an impact wrench.
3. Remove all traces of sealant from the mating surfaces of the cylinder block/crankcase connector, being careful not to damage the mating surfaces.
4. Remove the threaded plugs of the oil channels. It is unlikely that you will be able to unscrew them - carefully drill them out and run the threads with a tap, and install new plugs during assembly.
5. If the block is very dirty, it can be washed with pressure steam.
6. After cleaning the outer surfaces, clean all channels. Rinse them with hot water until the water runs clear. Dry thoroughly and apply a layer of oil to the treated surfaces to prevent corrosion. Also lubricate the cylinders of cast iron blocks/sleeves of aluminum blocks. If you have access to an air compressor, use it to speed up drying and blow out all ducts. After receiving the block from the workshop (if you handed it over for boring), washing and drying should be repeated.
Caution! Wear safety glasses when working with compressed air!
7. A block with minor dirt can be washed with hot water and soap and a stiff brush. It takes a fair amount of time to achieve good results. Regardless of the method used, all holes and channels of the block must be thoroughly cleaned and dried. After washing, the cast iron block should also be dried and lubricated with oil to prevent rust.
8. All threaded holes must be clean so that bolts can be tightened to the specified torque without fear of cracking the block. To remove rust, sealant residue and dirt from threaded holes and to restore the thread profile, run the holes with an appropriate tap. If possible, blow out the threaded holes with compressed air.
Caution! Wear safety glasses when cleaning holes with compressed air!
9. Apply a suitable sealant to the oil passage plugs and press or screw them into the block holes (depending on the design) and tighten securely. Apply sealant to the process plugs in the same manner and press them into place, using a piece of pipe or a socket head of the appropriate diameter as a mandrel.
10. If you do not plan to assemble the engine immediately, lubricate the cylinders and all mating surfaces with oil, cover it with plastic wrap and store it so that it does not rust prematurely.
Examination
11. Visually inspect the block for cracks and corrosion. Check the threaded holes for damage. If overheating or internal coolant leaks have occurred, the cylinder block must be inspected using special equipment to detect hidden cracks. If such defects are found, repair if possible; if not, replace the unit.
12. If you have any doubts about the condition of the cylinder block, have it checked by professionals at a specialized workshop. If the cylinders are heavily worn or damaged, they will help you take the necessary measurements and advise you on the possibility of restoring the block. They can also recommend a spare parts supplier. If the cylinders are worn out and it is not possible to obtain repair pistons, then there is only one solution - replacing the block.