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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 962 (Engine Mechanical - 6.6L (3 Of 5)) >> Off-Vehicle Repair Instructions (2 Of 4) >> Engine Block Cleaning and Inspection

Engine Block Cleaning and Inspection

WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: All remanufactured cylinder blocks are steel stamped on both sides of the fuel pressure pump boss. The stamp indicates whether the cylinder is standard or over-bored, and if the deck is standard or has been milled.
Engine Block Cleaning and Inspection

Stamped ID Cylinders Bore Size (in.) Top Deck (STD or Milled)
SS STD STD
01S 0.010 STD
02S 0.020 STD
03S 0.030 STD
SM STD Milled
01M 0.010 Milled
02M 0.020 Milled
03M 0.030 Milled
    Fig 1: Stampings
    GM1775614Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the block has no stampings, the block has a standard bore and deck.
  1. Inspect the block for stampings (1) indicating cylinder overbore or a milled deck.
    2. Fig 2: View Of Engine Block Heater
    GM1336124Courtesy of GENERAL MOTORS CORP.
  2. Remove the engine block heater.
  3. Remove the O-ring from the block heater and discard.
    4. Fig 3: View Of Oil Gallery Plug
    GM663096Courtesy of GENERAL MOTORS CORP.
  4. Remove the oil gallery plugs.
    5. Fig 4: View Of Left Engine Mount & Bolts
    GM881734Courtesy of GENERAL MOTORS CORP.
  5. Remove the left engine mount bolts.
  6. Remove the left engine mount.
    7. Fig 5: View Of Right Engine Mount & Bolts
    GM663100Courtesy of GENERAL MOTORS CORP.
  7. Remove the right engine mount bolts.
  8. Remove the right engine mount.
  9. Clean the sealing material from the gasket mating surfaces of the block.
  10. Clean the block in cleaning solvent.
  11. Flush the engine block with clean water or steam.
  12. Clean the oil passages.
  13. Clean the cylinder bores.
  14. Inspect the block for cracks. Use the Magnaflux Spot check dye method, or the equivalent.
    • Inspect the cylinder walls.
    • Inspect the coolant jackets.
    • Inspect the crankshaft bearing webs.
    15. Fig 6: View Of Crankshaft Bearing Bores & Caps
    GM663103Courtesy of GENERAL MOTORS CORP.
  15. Inspect the crankshaft bearing bores and caps. The crankshaft bearing bore inside diameters should be round and uniform at all of the bearing supports.
  16. Inspect the area where the crankshaft bearing inserts contact the crankshaft bearing bore. This area must be free of burrs and scratches.
  17. Inspect the engine mount bosses.
  18. Inspect the cylinder head gasket mating surfaces for pitting.
    19. Fig 7: Measuring Engine Block To Cylinder Head Gasket Surface Area
    GM35209Courtesy of GENERAL MOTORS CORP.
  19. Inspect the engine block to cylinder head gasket surface area for warping. Use a straight edge and feeler gauge. Replace the block if it is warped more than 0.15 mm (0.006 in) longitudinally or more than 0.08 mm (0.003 in) transversely.
  20. Apply sealer to the oil gallery plugs.
    21. Fig 8: View Of Oil Gallery Plug
    GM663096Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  21. Install the oil gallery plugs.

    Tighten:  Tighten the oil gallery plugs to 53 N.m (39 lb ft).

    22. Fig 9: View Of Left Engine Block Coolant Plugs
    GM1336125Courtesy of GENERAL MOTORS CORP.
  22. Install the left engine block coolant plugs.

    Tighten:  Tighten the left engine block coolant plugs to 18 N.m (13 lb ft).

    23. Fig 10: View Of Right Engine Block Coolant Plugs
    GM1397816Courtesy of GENERAL MOTORS CORP.
  23. Install the right engine block coolant plugs.

    Tighten:  Tighten the right engine block coolant plugs to 18 N.m (13 lb ft).

    24. Fig 11: View Of Left Engine Mount & Bolts
    GM881734Courtesy of GENERAL MOTORS CORP.
  24. Install the left engine mount and engine mount bolts.

    Tighten:  Tighten the engine mount bolts to 58 N.m (43 lb ft).

    25. Fig 12: View Of Right Engine Mount & Bolts
    GM663100Courtesy of GENERAL MOTORS CORP.
  25. Install the right engine mount and engine mount bolts.

    Tighten:  Tighten the right engine mount bolts to 58 N.m (43 lb ft).

    26. Fig 13: View Of Engine Block Heater
    GM1336124Courtesy of GENERAL MOTORS CORP.
  26. Install a new O-ring to the block heater.
  27. Lubricate the O-ring with engine coolant.
  28. Install the engine block heater.
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