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Engine Block Assemble > < Engine Support Fixture

Astra J

Engine Block Cleaning and Inspection

Special Tools

EN-8087   Gauge

For equivalent regional tools, refer to Special Tools .

Cleaning Procedure

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.
4. Dry the engine block with compressed air.

Visual Inspection

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.

Measuring Procedure

Engine Block Flatness Inspection


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

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

Cylinder Sleeve Diameter Inspection


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1. For classification the cylinder bore diameters see marking of the cylinder bore classification (1) on engine block.

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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 .
2. Inspect the cylinder bores using the EN-8087   gauge (1). Inspect for the following items:
  •  Wear of cylinder sleeve
  •  Cylinder sleeve diameter
  •  Tapering of cylinder sleeve
  •  Oval status of cylinder sleeve
  •  Refer to Engine Mechanical Specifications for the recommended limits.

Bearing Bore Diameter In Cylinder Block Inspection


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

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2. Install the lower crankcase (1).

Note:  Install without crankshaft and bearings for measure the bearing bore diameter in cylinder block.
3. Loosely install the 10 lower crankcase inner bolts (2).
4. Loosely install the 10 lower crankcase outer bolts (3).

Caution: Refer to Fastener Caution .

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5. Tighten the 10 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°

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6. Tighten the 10 lower crankcase outer bolts in sequence as shown to 30 N·m (22 lb ft) .

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7. For classification the bearing bore diameter in cylinder block see marking of the main bearing journal diameter classification (1) on crankshaft.

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

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

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12. Remove the 2 lower crankcase location pins (2).

Engine Block Assemble > < Engine Support Fixture