Cylinder Block

Cylinder Block








Cylinder Block and Associated Parts

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.

Caution: 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 inspect 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 straight edge 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.

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 al 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.

Note: For information on piston diameter, please refer to Inspection and Repair for the Piston and Connecting Rod.

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 prevent the crankshaft from rotating.
Tighten the flywheel bolts in 2 steps:
1st step: 65 Nm (48 ft. lbs.)
2nd step: 30° -45°

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 ft. lbs.)
2nd step: 45°
7. Install oil pump assembly.
8. Install oil strainer.
9. Install oil pan support.
10. Install oil pan assembly.