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    Bloque y Ciguenal

    Uploaded by

    Alejandro Valenzuela
    The document provides instructions for disassembling and assembling a crankshaft and cylinder block. It lists over 40 steps to remove components like the crankshaft, cylinder head, pistons, oil pan, and more. It then provides inspection and assembly instructions to reinstall the removed components in the reverse order.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Bloque y Ciguenal

    Uploaded by

    Alejandro Valenzuela
    35 views15 pages
    The document provides instructions for disassembling and assembling a crankshaft and cylinder block. It lists over 40 steps to remove components like the crankshaft, cylinder head, pistons, oil pan, and more. It then provides inspection and assembly instructions to reinstall the removed components in the reverse order.

    Original Description:

    KAICENE F70

    Original Title

    bloque y ciguenal

    Copyright

    © © All Rights Reserved

    Available Formats

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    The document provides instructions for disassembling and assembling a crankshaft and cylinder block. It lists over 40 steps to remove components like the crankshaft, cylinder head, pistons, oil pan, and more. It then provides inspection and assembly instructions to reinstall the removed components in the reverse order.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    35 views15 pages

    Bloque y Ciguenal

    Uploaded by

    Alejandro Valenzuela
    The document provides instructions for disassembling and assembling a crankshaft and cylinder block. It lists over 40 steps to remove components like the crankshaft, cylinder head, pistons, oil pan, and more. It then provides inspection and assembly instructions to reinstall the removed components in the reverse order.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 15

    3.5.2-90 Mechanical System 3.5.

    2-90

    Crankshaft and Cylinder Block

    Disassembly
    1. Disconnect the negative battery cable.
    Refer to: Battery (3.5.9 Charging System,
    Removal and Installation)

    2. Recycle the refrigerant.


    Refer to: A/C Refrigerant Recycling/
    Draining and Filling (4.1.1
    Heating, Ventilation and Air
    Conditioning, General
    Inspection)

    3. Drain the coolant.


    Refer to: Coolant Draining and Filling
    (3.5.4 Cooling System, General
    Inspection)
    4. Drain the engine oil.
    Refer to: Engine Oil Replacement (3.5.3
    Lubrication System, General
    Inspection)

    5. Remove the engine assembly.


    Refer to: Engine Assembly (3.5.2
    Mechanical System, Removal
    and Installation)

    6. Remove the cylinder head cover.


    Refer to: Cylinder Head Cover and
    Camshaft (3.5.2 Mechanical
    System, Disassembly and
    Assembly)

    P201 2020.01
    3.5.2-91 Mechanical System 3.5.2-91

    7. Remove the cylinder head.


    Refer to: Valve and Cylinder Head (3.5.2
    Mechanical System,
    Disassembly and Assembly)

    8. Remove the piston.


    Refer to: Piston and Connecting Rod
    (3.5.2 Mechanical System,
    Disassembly and Assembly)

    9. Remove the oil pan.


    Refer to: Oil Pan (3.5.3 Lubrication
    System, Removal and
    Installation)
    10. Remove the relief valve.
    Refer to: Relief Valve (3.5.3 Lubrication
    System, Removal and
    Installation)

    11. Remove the oil level gauge guide.


    Refer to: Oil Level Gauge Guide (3.5.3
    Lubrication System, Removal
    and Installation)

    12. Remove the oil suction pipe.


    Refer to: Oil Suction Pipe (3.5.3
    Lubrication System, Removal
    and Installation)
    13. Remove the oil cooler.
    Refer to: Oil Cooler (3.5.3 Lubrication
    System, Removal and
    Installation)

    14. Remove the oil pressure sensor.


    Refer to: Oil Pressure Sensor (3.5.3
    Lubrication System, Removal
    and Installation)

    15. Remove the oil pressure sensor.


    Refer to: Oil Pressure Sensor (3.5.3
    Lubrication System, Removal
    and Installation)

    16. Remove the water pump.


    Refer to: Water Pump (3.5.4 Cooling
    System, Removal and
    Installation)

    P201 2020.01
    3.5.2-92 Mechanical System 3.5.2-92

    17. Remove the fuel injection pump.


    Refer to: Fuel Injection Pump (3.5.7 Fuel
    System, Removal and
    Installation)

    18. Remove the compressor.


    Refer to: Compressor (4D25 Engine)
    (4.1.1 Heating, Ventilation and
    Air Conditioning, Removal and
    Installation)

    19. Remove the EGR cooler.


    Refer to: EGR Cooler (3.5.10 Emission
    Control System, Removal and
    Installation)

    20. Remove the crankshaft position sensor.


    Refer to: Crankshaft Position Sensor
    (3.5.13 Electronic Control
    System, Removal and
    Installation)
    21. Remove the clutch.
    Refer to: Clutch (3.2.2 Clutch, Removal
    and Installation)
    22. Hold the crankshaft, remove retaining bolt
    clockwise and remove crankshaft timing
    gear.

    P3502095

    23. Remove 12 retaining bolts and front cover.

    ×12

    P3502096

    P201 2020.01
    3.5.2-93 Mechanical System 3.5.2-93

    24. Remove the front oil seal from front cover.

    P3502126

    25. Secure the crankshaft, remove 4 retaining


    bolts and drive gear.

    ×4

    P3503025

    26. Remove 3 retaining bolts and oil pump.

    ×3

    P3503026

    27. Remove 3 retaining bolts and vacuum


    pump.

    ×3

    P3502122

    P201 2020.01
    3.5.2-94 Mechanical System 3.5.2-94

    28. Hold the flywheel, remove 8 retaining bolts


    and flywheel.

    ×8

    P3502106

    29. Remove the deep groove ball bearing from


    flywheel.

    P3502107

    30. Remove 6 retaining bolts and transition


    connecting plate.

    ×6

    P3502124

    31. Remove 5 retaining bolts and rear main


    bearing seat.

    ×5

    P3502125

    P201 2020.01
    3.5.2-95 Mechanical System 3.5.2-95

    32. Install two bolts into the two reserved thread


    holes on bearing seat, then tighten them
    evenly. Remove rear main bearing seat
    from engine body.
    ×2

    P3502097

    33. Remove 3 retaining bolts and speed sensor


    gear disk.

    P3502098

    34. Remove 3 balance shaft dowel pins with the


    balance shaft dowel pin remover.

    ×3

    P3502099

    35. Move out crankshaft from rear end of


    engine block.

    P201 2020.01
    3.5.2-96 Mechanical System 3.5.2-96

    36. Remove 2 center bearing seat retaining


    bolts (1).
    37. Remove 2 center bearing seats (2). 2

    38. Remove 2 center main bearing shells (3)


    from center bearing seat. 3

    P3502100

    39. Remove the remaining 2 center bearing


    seats.
    40. Remove the front main bearing shell with
    front main bearing shell remover.

    P3502101

    41. Install the cylinder liner remover to cylinder


    liner.

    P3502102

    P201 2020.01
    3.5.2-97 Mechanical System 3.5.2-97

    42. Tighten the bolt on cylinder liner remover,


    then remove cylinder liner.

    P3502103

    43. Remove cylinder liner copper gasket (1)


    and O-ring (2) from cylinder liner or cylinder
    block bore.

    P3502104

    44. Remove 4 retaining bolts and 4 fuel


    injection valves.

    P3502120

    Inspection
    1. Inspect the crankshaft thrust clearance.
    Standard value: 0.08 mm - 0.28 mm
    Limit value: 0.4 mm

    P3502105

    P201 2020.01
    3.5.2-98 Mechanical System 3.5.2-98

    Assembly
    1. Install 4 fuel injection valves and 4 retaining
    bolts.
    Torque: 10.8 N·m

    P3502120

    2. Clean cylinder liner and engine block


    carefully to remove oil at contact area
    between engine block and cylinder liner.
    Install the cylinder liner into engine block,
    and rotate the cylinder liner back and forth
    at 45° to ensure that the cylinder liner is
    correctly positioned.
    3. Secure a dial indicator to cylinder block top
    plane. After returning to zero of dial
    indicator based on cylinder block top plane,
    measure the sinkage distance of cylinder
    liner relative to the cylinder block (top
    plane).
    4. Move the dial indicator to edge of cylinder
    liner, and record the reading of dial
    indicator.
    5. Remove the cylinder liner.
    6. Select the appropriate cylinder liner copper
    gasket to ensure that edge of cylinder liner
    protrudes 0 ~ 0.05 mm from cylinder block
    top plane after cylinder liner is installed into
    cylinder block.
    7. Install the selected copper gasket (1) to
    cylinder liner, and install O-ring (2).
    8. Apply oil to positioning area between lower
    side of cylinder liner and cylinder block.
    1

    P3502104

    P201 2020.01
    3.5.2-99 Mechanical System 3.5.2-99

    9. Make sure that copper gasket is sealed in


    boss seat when installing the cylinder liner,
    then install cylinder liner installer, tighten
    bolts to compress cylinder liner. ×4

    10. Recheck that edge of cylinder liner


    protrudes 0 ~ 0.05 mm from cylinder block
    top plane

    P3502116

    11. Install the front main bearing shell.

    P3502117

    12. Install 2 center main bearing shells (3) to


    center bearing seat.
    13. Apply clean lubricant to crankshaft journal 2
    and bearing shell.
    14. Install 2 center bearing seats (2) to 3
    crankshaft.
    15. Install 2 center bearing seat retaining bolts
    (1).
    Torque: 44.1 N·m

    P3502100

    16. Install the remaining 2 center bearing seats.

    P201 2020.01
    3.5.2-100 Mechanical System 3.5.2-100

    17. Install the crankshaft to engine from rear


    end of engine block.

    CAUTION: Align the locating hole on


    bearing seat with locating hole on
    engine block when installing crankshaft
    assembly.
    18. Install 3 balance shaft dowel pins.

    ×3

    P3502119

    19. Install speed sensor gear disk and 3


    retaining bolts.
    Torque: 10.8 N·m

    P3502098

    20. Install rear main bearing seat and 5


    retaining bolts.
    Torque: 24.5 N·m

    ×5

    P3502125

    P201 2020.01
    3.5.2-101 Mechanical System 3.5.2-101

    21. Install transition connecting plate and 6


    retaining bolts.
    Torque for hexagon flange bolt: 45 N·m
    Torque for hexagon socket head cap bolt:
    78.5 N·m

    ×6

    P3502124

    22. Install the deep groove ball bearing to


    flywheel.

    P3502107

    23. Install flywheel and 8 retaining bolts.


    24. Diagonally tighten 8 flywheel retaining bolts.
    Tightening torque of first time: 50 N·m
    Tightening torque of second time: 75 N·m +
    90°
    ×8

    P3502106

    25. Install vacuum pump and 3 retaining bolts.


    Torque: 10.8 N·m

    ×3

    P3502122

    P201 2020.01
    3.5.2-102 Mechanical System 3.5.2-102

    26. Install oil pump and 3 retaining bolts.


    Torque: 10.8 N·m

    ×3

    P3503026

    27. Install drive gear and 4 retaining bolts.


    Torque: 10.8 N·m

    ×4

    P3503025

    28. Place the installer around the hole of front


    oil seal, then apply a small amount of oil to
    lip of front oil seal and install front oil seal to
    fitting tool, then press the front oil seal into
    front cover.

    P3502121

    29. Apply sealant to front cover.

    P3502123

    P201 2020.01
    3.5.2-103 Mechanical System 3.5.2-103

    30. Install front cover and 12 retaining bolts.


    Torque: 11.8 N·m

    ×12

    P3502096

    31. Install the crankshaft timing gear, and install


    retaining bolt counterclockwise.
    Torque: 275 N·m

    P3502095

    32. The remaining installation procedures are in


    the reverse procedures of removal.

    P201 2020.01

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