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4. Remove engine front cover, accessory drive pulley,
timing belt lower cover and crankshaft timing sprocket, using
Tool J 23523.
5. Remove oil pan and baffle and oil pick-up tube.
6. Remove oil pump (crankcase front cover).
7. Check the connecting rod caps for cylinder number
identification. If necessary, mark caps with corresponding
cylinder number.
8. Remove the connecting rod caps and push the pistons
to top of bores.
9. Remove main bearing caps and lift crankshaft out of
cylinder block.
10. Remove rear main bearing oil seal and main bearings
from cylinder block and main bearing caps.
Cleaning and lnspection
1. Wash crankshaft in solvent and dry with compressed
air.
2. Measure dimensions of main bearing journals and
crankpins with a micrometer for out-of-round, taper or
undersize (see specification).
3. Check crankshaft for run-out by supporting at the
front and rear main bearings journals in
"V"
blocks and
check at the front and rear intermediate journals with a dial
indicator.
4. Replace or recondition the crankshaft if out of
specifications.
CYLINDER BLOCK
Cleaning and lnspection
1. Remove engine and disassemble as outlined under
Crankshaft Removal.
2. Remove the cylinder head assembly.
3. Wash cylinder block thoroughly in an approved
noncaustic cleaning solvent.
4. Clean and inspect all gasket surfaces.
5. Remove oil gallery plugs and clean all oil passages.
NOTE: These plugs may be removed with a sharp punch
or they may be drilled and pried out.
6. Use a ridge reamer to remove any ridge and/or
deposits from the upper end of the cylinder bore.
7. Clean cylinder bores with a hot water and detergent
wash. After cleaning the cylinder bores should be swabbed
several times with light engine oil and a clean cloth, and then
wiped with a clean dry cloth. Cylinders should not be cleaned
with kerosene or gasoline.
8. Measure the cylinder walls for taper and out-of-round.
This should be done with a dial indicator. Set the gage so that
the thrust pin must be forced in about 1/4" when installing
gage in bore. Center gage in cylinder and turn dial to zero.
Carefully work gage up and down cylinder to determine taper
and turn it to different points around cylinder wall to
determine the out-of-round condition.
Oil Filter Bypass Valve
With the oil pump removed, check the spring and fiber
valve for operation. Inspect for a cracked or broken valve.
If replacement is necessary, remove valve by prying it out
with a screwdriver. Install and seat a new valve by tapping
it in place, using a 9/16" thin-wall deep socket.
REPAIRS
Cylinder Conditioning
In the event that bores are excessively scored or worn,
they can be honed in the conventional manner with either
manual or machine honing equipment for oversize pistons;
however, the finishing step must be a silicon lapping process
to achieve the finished bore surface required. The silcon lap
is used to remove a sufficient amount of aluminum, leaving
pure silicon particles prominent to form the bore wear
surfaces.
Honing Procedures
Conventional honing equipment
-
either manual or
machine
-
can be used. The manufacturers of this equipment
are familiar with the requirements and can supply the
required information and material for their equipment. Use
only a fatty base honing oil (Sunnen Man-845 or equivalent).
Do not use mineral seal type oil. Use commercially available
honing equipment which will operate at approximately 350
rpm
.
Roughing Operation
Use a 280 grit roughing stone set (manual
-
Sunnen
MM33-J63, machine
-
Sunnen C30-A53-81; or equivalent).
Stock removal rate will be approximately .0035" per minute.
Hone to within .003" of finished size; surface finish will be
approxmiately 25-30 micro inches. During the honign
operation, flood cylinder with specified honing oil, using a
continual spray pump or apply continuously with an oil squirt
can.
Finishing Operation
Use a 400 grit finishing stone set (manual
-
Sunnen
MM33-J85, machine
-
Sunnen C30-584-81; or equivalent).
Stock removal rate will be approximately .002" per minute.
Remove approximately .002" stock, surface finish will be
approximately 20-25 micro inches. Flood with specified
honing oil same as during roughing operations.
Polishing Operation
Prior to this operation, be sure that all traces of the
previous finishing operation abrasives are removed. Use a 600
grit polishing stone set (manual
-
Sunnen MM33-C05,
machine
-
Sunnen C30-(33-81; or equivalent). Stock removal
rate is approximately .0007" per minute with a maximum
surface finish of 8 micro inches. Keep stone tension against
cylinder wall fairly tight and remove approximately .00lW.
Flood bore with specified honing oil.
Silicon Lap
For silicon lapping, mount felt lapping pads in hone in
place of stones. Remove guides or replace with lapping pads.
Generously coat cylinders and pads with lapping compound
(Sunnen M33 or equivalent). Tighten pinion adjustment as
snugly as possible with fingers. Lap for two minutes using no
oil. Surface finish will be approximately 12-35 micro inches.
There will be no significant stock removal during the lapping
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