Cylinder Block Assembly: Service and Repair

1. Perform steps 1 through 9 of cylinder head service procedure.
2. Remove flywheel or driveplate housing cover.
3. Lock crankshaft using crankshaft stopper tool No. 498497100 or equivalent, then remove flywheel or driveplate.
4. Remove oil separator cover.
5. Remove water pump.
6. Remove oil pump retaining bolts, then using a flat blade screwdriver, separate oil pump from cylinder block. Use caution not to scrape mating surfaces.
7. Position cylinder block with No. 2 and 4 pistons facing upward.
8. Remove oil pan retaining bolts, then using oil pan cutter tool separate oil pan from cylinder block. Use caution not to scrape mating surfaces.
9. Remove oil strainer stay, oil strainer, baffle plate and oil filter.
10. Remove pistons as follows:
a. Remove service hole cover and plugs from both sides of crankcase.
b. Rotate crankshaft until pistons for No. 1 and No. 2 cylinders are at BDC.
c. Working through access holes, remove piston pin circlips for No. 1 and No. 2 pistons.
d. Using piston pin remover tool No. 499097500 or equivalent, withdraw piston pins for No. 1 and No. 2 pistons.
e. Repeat step 10 for cylinders 3 and 4 respectively.
11. Separate crankcase as follows:
a. Remove crankcase half retaining bolts from No. 2 and 4 cylinder side of block.
b. Loosen crankcase half retaining bolts from No. 1 and 3 cylinder side of block. Do not remove bolts at this time.
c. Position crankcase so that cylinders No. 1 and 3 face upward.
d. Remove retaining bolts and separate crankcase halves. Use caution so connecting rod will not damage cylinder block.
12. Remove rear oil seal.
13. Remove crankshaft and connecting rod assembly.
14. Remove crankshaft bearings from crankcase halves keeping them in order.
15. Mark and remove pistons from crankcase halves, and mate pistons with respective pins.
16. Remove connecting rod caps and rod bearings. Keep all components in order to ensure proper assembly. Components that are to be reused should be installed in original position.
17. Remove piston rings using a piston ring expander. Remove oil ring by hand.
18. Remove circlip.
19. Ensure all components are clean and free from foreign material, and that oil passages are clear. Coat all friction surfaces with oil or suitable assembly lubricant.
20. Connecting Rod installation:
a. Seat connecting rod bearings in caps and rods, then coat bearing with clean engine oil.
b. Ensure connecting rod and cap matching marks are aligned, and install connecting rod assemblies with mark facing forward.
c. Lubricate connecting rod bolt threads and ensure bolts are properly seated in cap and that caps are fully seated against connecting rods.
d. Evenly tighten connecting rod nuts to specifications.
21. Install main bearings into crankcase halves, then coat bearing with clean engine oil.
22. Install crankshaft into lefthand crankcase.
23. Clean crankcase half mating surfaces with suitable solvent, then apply a thin bead of Three-Bond 1215 or equivalent sealant to one crankcase half. Ensure sealant does not enter oil or coolant passages.

Fig. 41 Crankcase Bolt Tightening Specifications:

24. Guide righthand crankcase half onto left case, then install and torque retaining bolts as follows:
a. Torque bolts on No. 1 and 3 cylinder side of block to 14-22 ft. lbs.
b. Position cylinder block horizontally.
c. Torque all retaining bolts to specifications as shown in Fig. 41, beginning with No. 1 and 3 cylinder side of block.

Fig. 42 Piston Ring Installation:

25. Install piston rings onto pistons, positioning end gaps as shown, Fig. 42. After installation, bend pawl of upper oil ring rail upward and attach to hole in piston.
26. Piston installation:
a. Prior to insertion, coat piston, piston pin and pin guide with clean engine oil.
b. With No. 1 and 2 cylinders facing upward, turn crankshaft until No. 1 and 2 connecting rods are positioned at BDC.
c. Insert piston into cylinder, align piston pin hole and connecting rod small end with pin guide tool No. 499017100 or equivalent, then install piston pin through access hole.
d. Install piston pin circlip.
e. Repeat step 26 for cylinders 3 and 4 respectively.
27. Apply Three-Bond 1105 or equivalent sealant, then install service access hole plugs and cover with new gaskets. Tighten plugs to specifications.
28. Coat outside surface of rear seal with engine oil, and seal lip with grease, then install oil seal using a suitable tool.
29. Apply Three-Bond 1207C or equivalent sealant, then install oil separator cover with new gasket and Tighten to specifications.
30. Install flywheel or driveplate and tighten bolts to specifications.
31. Apply Three-Bond 1215 or equivalent sealant to oil pump to cylinder block mating surface. Align flat surface of inner rotor with crankshaft and install oil pump assembly with new seal and O-ring. Tighten bolts to specifications.
32. Install water pump with new gasket. Tighten bolts to specifications.
34. Install baffle plate, oil strainer, stay and oil pan. Tighten bolts to specifications.
35. Install oil filter.
36. Install flywheel or driveplate housing cover.
37. Finalize installation by performing steps 14 through 22 of cylinder head service procedure.