Cylinder Block

CYLINDER BLOCK





Tool Required: J 8087 Cylinder Bore Checking Gage

Disassemble
1. Oil filter adapter bolt (43).
2. Oil filter adapter (41) and gasket (40).
3. Knock sensor.
4. Ignition timing sensor retaining bolt (66) and sensor (67)
5. Camshaft sensor retaining bolt (95).
6. Camshaft sensor (96).
7. Coolant jacket plugs (74).
8. Coolant jacket threaded plugs (69 and 70).
9. Oil gallery plugs (64, 65, 78 and 79).



Important
^ Caustic cleaning solution destroys the bearing material. All bearings must be replaced after cleaning with a caustic solution. Do not clean bearing material or aluminum parts with caustic solutions.


Clean
^ Sealing material from mating surfaces.
^ Boil in caustic solution.
^ Flush with clean water or steam.
^ Oil passages.
^ All blind holes.
^ Spray or wipe cylinder bores and machined surfaces with engine oil.


Inspect





^ Check surface for flatness. Use a straight edge and a feeler gage (Figure 26).
- If the cylinder head deck flatness exceeds 0.1 mm (0.004 inch), the surface should be machined flat.
- If more than 0.25 mm (0.010 inch) must be removed, replace the block.

^ Oil pan rail and timing cover attaching area for nicks. Minor irregularities may be cleaned up with a flat mill file.
^ Head bolt tapped holes.
^ Transaxle case mating surface.

NOTICE: If this surface is not flat, a broken flywheel may result.

^ Temporarily install the crankshaft and measure crankshaft flange run-out.


Measure





^ Cylinder block flange surface runout at six mounting hole bosses (Figure 27).
- Hold gage plate flat against the crankshaft flange (Figure 27).





- Place dial indicator stern on the transaxle mounting bolt hole boss (Figure 28) and set indicator to 0 mm (0 in.).

- Take and record the readings obtained on the remaining transaxle mounting bolt hole bosses (Items A-F, Figure 27).
Measurements should not vary more than 0.25 mm (0.010 inch).

- If the readings vary more than 0.25 mm (0.010 inch), recheck crankshaft flange run-out. If the run-out is excessive, replace the crankshaft.



Inspect
1. Threaded holes.
- If necessary, clean with a tap or drill out and install thread inserts.

Important
^ The following inspections as well as reconditioning, if necessary, must be carried out with the main bearing caps installed and tightened to specification.
^ Make sure main bearing caps are installed correctly, with the arrows pointing toward the front of the engine.








2. Camshaft and Crankshaft bearing bores, using J 8087, measure concentricity and alignment.
3. Cylinder bore, with J 8087 measure for wear, taper, run-out and ridging (Figures 29 and 30).

^ If the bore is worn out of specifications, it may be rebored, honed and fitted with oversize pistons. The smallest available oversize should be selected.

Important
^ Leave sufficient material to allow finish honing in conjunction with fitting the piston.
^ If the bore is glazed but otherwise serviceable, break the glaze lightly with a hone and replace the piston rings.
^ Make sure the honing stones are clean, sharp and straight. Move the hone slowly up and down to produce a cross-hatch pattern. Clean bore thoroughly with soap and water. Dry and rub in clean engine oil, then measure.