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Home >> Pontiac >> 2002 >> Aztek AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (Unit Repair) >> Repair Instructions >> Engine Block Cleaning and Inspection >> Tools Required

Tools Required

  1. Clean the sealing material from the gasket mating surfaces.
  2. Boil the engine block in caustic solution.
  3. Flush the engine block with clean water or steam.
  4. Clean the oil passages.
  5. Clean the bind holes.
  6. Spray the cylinder bores and the machined surfaces with engine oil.
  7. Inspect the threaded holes.
  8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
    Fig 1: Cleaning Inspecting Engine Block
    G01745521Courtesy of GENERAL MOTORS CORP.
  9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.25 mm (0.010 in) must be removed.
  10. Inspect the oil pan rail for nicks.

    Inspect the front cover attaching area for nicks.

    Use a flat mill file in order to remove any nicks.

    Fig 2: Testing Deck Surface For Flatness
    G01745522Courtesy of GENERAL MOTORS CORP.
  11. Inspect the mating surfaces of the transmission case.
    NOTE: A broken flywheel may result if the transmission case mating surface is not flat.
  12. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt hole bosses:
    1. 12.1 Temporarily install the crankshaft. Measure the crankshaft flange runout.
    2. 12.2 Hold the J 8001  gage plate flat against the crankshaft flange.
    3. 12.3 Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.
      Fig 3: Measuring Engine Block Flange Runout
      G01745523Courtesy of GENERAL MOTORS CORP.
    4. 12.4 Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.25 mm (0.010 in).
    5. 12.5 Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the crankshaft flange runout is within the specification, replace the engine block.

    Important:  Perform the following inspections, and reconditioning (if necessary), with the crankshaft main bearing caps installed and tightened to specification.

  13. Inspect the crankshaft main bearing bores. Use the J 8087  in order to measure the bearing bore concentricity and alignment at the following locations:
    • The camshaft
    • The crankshaft
  14. Replace the engine block if the bores are out of specification.
    Fig 4: Measuring Bearing Bore Concentricity And Alignment
    G01745524Courtesy of GENERAL MOTORS CORP.
  15. Use the J 8087  in order to inspect the cylinder bores. Inspect the bores for the following conditions:
    • Wear
    • Taper
    • Runout
    • Ridging
    IMPORTANT: If the bore is worn beyond the limits, refit the bore with 0.5 mm (0.02 in) oversized pistons.
  16. Leave sufficient material in order to allow honing when fitting the piston.
    Fig 5: Measuring Cylinder Bore
    G01745525Courtesy of GENERAL MOTORS CORP.
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