Cylinder Block Assembly: Service and Repair

Cylinder block, crankshaft and flywheel, disassembling and assembling

Note: Replace all gaskets and seals.
1. Thrust washers
^ Measuring axial clearance of crankshaft.
^ Thrust washer only fitted on 4th crankshaft bearing
2. Special bolt (double hexagon)
^ Always replace
^ Dual mass flywheel: 60 Nm + 180° (1/2 turn)
3. Dual mass flywheel
^ Removing and installing, Refer to Transmission and Drivetrain.
^ Removing and installing needle bearing, Refer to Transmission and Drivetrain.
4. Crankshaft bearing
^ Checking axial and radial clearance, Refer to Crankshaft Engine, Service and Repair.
5. Bolt, tightening torque 10 Nm
6. oil spray jet
^ For piston cooling
7. Oil seal for rear sealing flange
^ Replacing, Refer to, Seals and Gaskets, Engine, Crankshaft Main Bearing Seal, Service and Repair.
8. Bolt, tightening torque 10 Nm
9. Rear sealing flange
10. Gasket
11. Bolt, tightening torque 25 Nm
^ Screw in bolts on left and right sides finger tight before tightening bolts on main bearing caps.
12. Cylinder block
13. Gasket
14. Collar bolt, tightening torque 30 Nm
^ Apply Loctite when installing
15. Bolt, tightening torque 10 Nm
16. Front sealing flange
17. Expansion pins
18. Crankshaft
^ Checking, Refer to Crankshaft Engine, Service and Repair.
19. Chain sprocket for oil pump.
20. Pistons
^ Checking, Refer to Piston Engine, Testing and Inspection.
21. Piston rings
^ Checking, Refer to Piston Engine, Testing and Inspection.
22. Circlip for piston pin
23. Piston pin
24. conrod
^ Mark cylinder number and installation position of matching conrods and bearing caps before removing
^ Installation position: wider, slightly convex machined surfaces on the same side
25. conrod bearing
^ Do not interchange used bearing shells.
^ Connecting rods, connecting rod bearings, Refer to Connecting Rod, Engine, Testing and Inspection.
26. Conrod bearing bolts
^ Always replace
^ Tightening torque: 30 Nm + 90 (1/4 turn)
^ When measuring radial clearance, tighten to 20 Nm but do not turn further.
27. Main bearing cap
^ Marking -1- on oil pump side
^ Renew bolts for main bearing caps
^ Watch position of dowel sleeves
^ Checking bearing clearance, Refer to Crankshaft Engine, Service and Repair.
28. Bolts for main bearing caps
^ Always replace
^ Tightening torque, Refer to Crankshaft Main Bearing, Service and Repair.
^ Tightening sequence, Refer to Crankshaft Main Bearing, Service and Repair.