Cylinder block (J and К

models) - removal, inspection;i4,
and installation ^

Note: To remove the cylinder block, the engine must be removed from ihe frame (see Section 5).

Removal

1 Remove the engine (see Section 5).

2 Remove the cylinder head (see Section 10) and the camshaft drive gear assembly (see Section 13).

3 Slacken the clamp securing the coolant hose to the union on the back of the cylinder block and detach the hose (see illustration).

4 Unscrew and remove the single bolt located in the back of the camshaft drive gear tunnel (see illustration).

5 Lift the cylinder block up off the crankcase (see illustration). If the block is stuck, tap around the joint faces of the block with a soft-faced mallet to free it from the crankcase. Don't attempt to free the block by inserting a screwdriver between it and the crankcase -you'll damage the sealing surfaces. When the block is removed, stuff clean rags around the pistons to prevent anything falling Into the crankcase. Remove the dowels from the mating surface of the crankcase or the underside of the block if they are loose. Be careful not to let these drop into the engine.

6 Remove the gasket and clean all traces of old gasket material from the cylinder block and crankcase mating surfaces. If a scraper is used, take care not to scratch or gouge the soft aluminium, Be careful not to let any of the gasket material fall into the crankcase or the oil passages.

14.3 Slacken the clamp and detach the hose...

ГСД7ТТ?! Rotate the crankshaft until ШшШВЛ _ihe i_nner pistons _але

HI NT uppermost and feed them

Into the block first. This makes access to the lower pistons easier when compressing the rings and feeding them into the bores.

Inspection

7 Refer to Section 22.

Installation

8 Check that Ihe mating surfaces of the cylinder block and crankcase are free from oil or pieces of old gasket. If removed, fit the dowels into the crankcase.

9 Remove the rags from around the pistons, and lay the new base gasket in place on the crankcase making sure all the holes are correctly aligned. Never re-use the old gasket.

10 If required, install piston ring clamps onto the pistons to ease their entry into the bores as the block is lowered. This is not essential as each cylinder has a good lead-in enabling the piston rings to be hand-fed into the bore. If possible, have an assistant support the block while this is done.

11 Lubricate the cylinder bores, pistons and piston rings, and the connecting rod big- and

14.4... then unscrew the bolt (arrowed)...

small-ends, with clean engine oil, then install the block down onto the studs until the uppermost piston crowns fit into the bores (see illustration).

12 Gently push down on the cylinder block, making sure the pistons enter the bore squarely and do not get cocked sideways. If piston ring clamps are not being used. carefully compress and teed each ring into the bore as the block is lowered. If necessary, use a soft mallet to gently tap the block down, but do not use force if the block appears to be stuck as the pistons and/or rings will be damaged. If clamps are used, remove them once the pistons are in the bore.

13 When the pistons are correctly installed in the cylinders, press the block down onto the base gasket, making sure it locates correctly onto the dowels.

14 Install the single bolt into the rear of the camshaft drive gear tunnel and tighten it to the torque setting specified at the beginning of the Chapter (see illus­tration 14.4).

15 Attach the cooant hose to the union on the back of the cylinder block and tighten the clamp (see illustration 14.3).

16 Install the camshaft drive gear assembly (see Section 13) and the cylinder head (see Section 10).

17 Install the engine (see Section 5).

14.5... and remove the block

Дата добавления: 2015-10-29