Spark

Engine Block Cleaning and Inspection

1. Remove any old thread sealant, gasket material or sealant.
2. Clean all the following areas with solvent:

•	Sealing surfaces

•	Cooling passages

•	Oil passages

•	Bearing journals

3. Clean all threaded and through holes with solvent.

Warning: Refer to Safety Glasses and Compressed Air Warning in the Preface section.

4. Dry the engine block with compressed air.

1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the engine block assembly must be replaced.
2. Inspect all sealing and mating surfaces for damage, repair or replace the engine block assembly if necessary.
3. Inspect all threaded and through holes for damage or excessive debris.
4. Inspect all bolts for damage, if damaged replace with NEW bolts only.
5. Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the cylinders are damaged the cylinder block assembly must be replaced.
6. Inspect the engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block assembly must be replaced.

Engine Block Flatness Inspection

1. Inspect the engine block as shown for distortion. Use a straightedge (1).



2. Inspect the engine block as shown for deflection. Use a straightedge (1).

Cylinder Sleeve Diameter Inspection

Note: If the cylinder sleeve measurements are not within the recommended limits, ream the cylinder bores with the recommended oversizes. Refer to Engine Mechanical Specifications

Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items:

Bearing Bore Diameter In Cylinder Block Inspection

1. Install the 2 lower crankcase location pins (3).



2. Install the lower crankcase (1)

Note: Install without crankshaft and bearings to measure the bearing bore diameter in cylinder block.

3. Loosely install the 8 lower crankcase inner bolts (2).
4. Loosely install the 8 lower crankcase outer bolts (3).

Caution: Refer to Fastener Caution in the Preface section.




5. Tighten the 8 lower crankcase inner bolts in sequence as shown and in the following order:

•	Tighten the bolts in sequence as shown to 20 N·m (15 lb ft)

•	Tighten in sequence as shown to an additional 80 °




6. Tighten the 8 lower crankcase outer bolts in sequence as shown to 30 N·m (22 lb ft).



7. Inspect the bearing bore diameter in cylinder block using the EN-8087 gauge (1). Refer to Engine Mechanical Specifications for the recommended limits.



8. Remove the 8 lower crankcase outer bolts (3).
9. Remove the 8 lower crankcase inner bolts (2).
10. Remove the lower crankcase (1).