Cylinder Block Assembly: Service and Repair
DISASSEMBLY
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove oil pan assembly.
4. Remove oil pan support.
5. Remove oil strainer.
6. Remove oil pump assembly.
7. Remove balance unit assembly.
8. Remove piston and connecting rod assembly.
9. Remove flywheel.
10. Remove rear oil seal retainer assembly.
11. Remove main bearing cap.
12. Remove crankshaft.
13. Remove cylinder block.
INSPECTION AND REPAIR
1. Remove the cylinder head gasket and any other material adhering to the upper surface of the cylinder block. Be very careful not to allow any material to accidentally drop into the cylinder block. Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal retainer, and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use a flaw detector to perform a dye penetrate and hydraulic (or air pressure) test. If cracking or other damage is discovered, the cylinder block must either be repaired or replaced.
Flatness
1. Using a straightedge and feeler gauge, check that the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the warpage exceeds the limit.
Warpage
Limit: 0.40 mm (0.0156 inch)
Maximum repairable limit: 0.40 mm (0.0156 inch)
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore diameter in both the axial and thrust directions. Each measurement should be made at six points.
CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block.
If the measurement exceeds the specified limit, the cylinder block must be replaced.
Diameter
Grade 1: 85.975 mm - 85.985 mm (3.3530 inch 3.3534 inch)
Grade 2: 85.985 mm - 86.025 mm (3.3534 inch 3.3550 inch)
Oversize: 0.5 mm (0.0195 inch)
NOTE: For information on piston diameter, please refer to Testing and Inspection of the Piston and Connecting Rod Assembly.
REASSEMBLY
1. Install cylinder block.
2. Install crankshaft.
- Install the main bearings to the cylinder block and the main bearing caps.
- Be sure that they are positioned correctly.
- Apply new engine oil to the upper and lower main bearing faces.
NOTE: Do not apply engine oil to the bearing back faces.
- Carefully mount the crankshaft.
- Apply engine oil to the thrust washer.
3. Install rear oil seal.
- Coat lip of seal rings thinly with protective grease.
- Install seal ring into cylinder block, use J-42616 (1) and J-42613 (2).
4. Install flywheel
1. Thoroughly clean and remove the oil from the threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then install the washer.
4. Use stopper (J-42618) to hold the crankshaft.
Prevent from rotating.
Tighten the flywheel bolts in 3 steps:
1st step: 65 Nm (48 ft. lbs.)
2nd step: 30°
3rd step: 15°
NOTE: Do not reuse the bolt.
5. Install piston and connecting rod assembly.
- Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins.
NOTE: Do not apply engine oil to the bearing back faces.
- Position ring gaps:
1-Compression rings 180° to each other as illustrated (A).
2-Offset oil control rings 25 to 50 mm /1 to 2 inch from gap of second compression ring (B).
6. Install balance unit assembly and tighten the bolts in 2 steps in the order shown:
1st step: 20 Nm (14 1b ft)
2nd step: 45°
7. Install oil pump assembly, refer to Oil Pump.
8. Install oil strainer.
9. Install oil pan support.
10. Install oil pan assembly.
1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB-1207C or its equivalent) to the contact surfaces of the crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes after sealant application.
4. Tighten the bolts and nuts to the specified torque in 2 steps:
1st step: 8 Nm (5.8 ft. lbs.)
2nd step: 30°
11. Install cylinder head gasket.
12. Install cylinder head assembly, refer to Cylinder Head.