Section 02 ENGINE
Subsection 11 (CYLINDER BLOCK)
GENERAL
When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.),
it is strongly recommended to note their position
(cylinder 1, 2 or 3) and to keep them as a “group”.
If you find a defective component, it would be
much easier to find the cause of the failure within
the group of parts. Besides, since used parts
have matched together during the engine oper-
ation, they will keep their matched fit when you
reassemble them together within their “group”.
During asse
mbly/installation, use torque values
and service
products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to
SELF-LOCKING FASTENERS
and
LOCTITE
APPLICATION
at the beginning of this manual for
complete procedure.
WARNING
Torque wre
nch tightening specifications
must be str
ictly adhered to.
Locking de
vices (e.g.: locking tabs, elastic
stop nuts
, self-locking fasteners, cotter pins,
etc.) mus
t be replaced with new ones.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to
EN-
GINE MANAGEMENT
section.
UNUSUAL ENGINE NOISE OR
VIBRATIONS
1. Heavy wear on plain bearings
- Check radial play of plain bearings.
- Replace plain bearings if out of specification.
2. Crankshaft and balancer shaft are not properly
aligned
- Disassemble cylinder block and check if marks
are properly aligned.
3. Crankshaft or balancer shaft axial play out of
specification
- Measure crankshaft and balancer shaft axial play.
- If axial play is out of specification, replace thrust
washers.
4. Connecting rod axial play out of specification
- Measure connecting rod axial play on crankshaft.
- Replace connecting rod or crankshaft if out of
specification.
5. Connecting rod screws got loose
- Replace damaged components and retighten
screws with the recommended torque.
BLUE SMOKE IN THE EXHAUST
1. Oil scrapper rings worn out
- Replace piston rings.
ENGINE SUDDENLY TURNS OFF (POOR
IDLING)
1. Piston rings worn out
- Replace piston rings.
2. Piston/cylinder wall clearance out of specifica-
tion
- Check piston/cylinder wall clearance.
- Replace if out of specification.
3. Melted or broken piston
- Check if oil spray nozzle is not clogged. Refer to
LUBRICATION SYSTEM subsection.
- Replace piston and cylinder block if necessary.
PROCEDURES
TIMING CHAIN
Timing Chain Inspection
Check timing chain on camshaft gear for exces-
sive radial play.
Check chain condition for wear and rollers condi-
tion.
1
R610motr201A
1. Timi
ng chain
If chain is excessively worn or damaged, replace
it as a set (camshaft timing gear and timing chain).
152 smr2009-026
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