Cylinder Block Assembly: Service and Repair

DISASSEMBLY
Engine Block

Fig. 18 Engine Outer Components (Part 1 Of 2):

Fig. 22 Main Bearing Cap Bolt Loosening Sequence:

Fig. 23 Main bearing cap bolt loosening sequence:

With the timing belt removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact.
1. Remove engine as outlined under Engine.
2. Remove remaining engine outer components, Fig. 18.
3. Place engine on suitable work stand.
4. Drain engine oil.
5. Remove timing belt. Refer to Timing Belt for procedure.
6. Remove oil pan. Refer to Oil Pan, Engine for procedure. Next remove the oil pump. Refer to Oil Pump, Engine for procedure.
7. Remove rear oil seal retainer, then remove water pump. Refer to Water Pump for procedure.
8. Remove cylinder heads. Refer to Cylinder Head Assembly for procedure.
9. Place suitable match marks on pistons, rods and rod caps for later assembly.
10. Remove rod bolts and caps, then remove piston and rod assemblies. Remove bearing caps bolts in sequence, then crankshaft, Figs. 22 and 23.

Fig. 24 Exhaust manifold bolts loosening sequence:

1. Remove exhaust manifolds, loosen attaching bolts in sequence, Fig. 24, then remove cylinder head as outlined under Cylinder Head Assembly.
2. Place suitable match marks on components for later assembly.
3. Measure camshaft endplay. Endplay should be 0.0012-0.0031 inch.
4. Loosen camshaft bearing caps in three stages Fig. 17, then remove caps and camshafts.
5. Remove hydraulic valve lifters, maintain order of disassembly for later reassembly.
6. Using valve spring compressor tool No. J33986, or equivalent, remove valve component parts and valve guide seals.
7. Clean then inspect components for wear, cracks and warpage.
8. Using a suitable piston ring expander tool, remove piston rings.
9. Remove piston pin snap rings.
10. Place pistons in suitable heated oil bath at 140-158°F, or press piston assembly using a suitable piston pin press.
11. Using suitable driver, push out pin.

Piston and Rod Assembly
1. Using a suitable piston ring expander tool, remove piston rings.
2. Remove piston pin snap rings.
3. Place pistons in suitable heated oil bath at 140-158°F, or press piston assembly using a suitable piston pin press.
4. Using suitable driver, push out pin.

Fig. 29 Main bearings:

Fig. 30 Main bearings cap bolt tightening sequence:

ASSEMBLY
Engine Block
1. Set main bearings in proper position on cylinder block, Fig. 29. If cylinder block, crankshaft or main bearing is reused, main bearing clearance must be measured. Upper bearings have oil groove.

2. If crankshaft, cylinder block and main bearing are replaced, thickness of main bearings must be selected as follows:
a. Grade No. of each cylinder block main journal is punched on respective cylinder block.
b. Grade No. of each crankshaft main journal is punched on respective crankshaft.
c. Select main bearing whose thickness grade is equal to sum of thickness grades of crankshaft journal and main journal.

3. Apply engine oil to main bearing surfaces on both sides of cylinder block and cap.
4. Install crankshaft and main bearing caps, then using sequence shown in Fig. 30, torque bolts in two or three steps to 67-74 ft. lbs.
5. Ensure crankshaft turns smoothly by hand.
6. Measure crankshaft free endplay at No. 4 bearings follows:
a. Clearance should be 0.0020-0.0071 inch.
b. If clearance exceeds 0.0118 inch, replace No. 4 main bearing or crankshaft as required.

7. Install pistons with connecting rods in proper cylinders, noting the following:
a. Ensure not to scratch cylinder wall with connecting rod.
b. Apply engine oil to cylinder wall, piston and bearing.
c. Install into engine so that front mark on piston head faces toward front of engine.
d. Install connecting rod bearing caps and torque connecting rod nuts to 10-12 ft. lbs., then turn bolts an additional 60-65° clockwise or if angle wrench is not available, torque bolts to 28-33 ft. lbs. on single overhead cam engines or 43-48 ft. lbs. on double overhead cam engines.

8. Measure connecting rod side clearance. Clearance should be 0.0079-0.0138 inch. If clearance exceeds 0.0157 inch, replace connecting rod and/or crankshaft.
9. Install oil pump, rear seal retainer, oil pan, water pump, cylinder heads, and timing belt. Refer to Engine for proper procedures.

Fig. 35 Piston & rod assembly:

Fig. 36 Piston Skirt & "a" Dimension Measurements:

Fig. 37 Piston Skirt & "a" Dimension Measurements:

Piston and Rod Assembly
1. Install new snap ring on one side of piston pin hole, heat piston to 140-158°F and assemble piston, pin connecting rod and snap ring.
2. Align direction of piston and connecting rod. Ensure numbers stamped on connecting rod and cap correspond to each cylinder, Fig. 35.
3. Refer to Fig. 36 and 37 for piston skirt measurements.
4. After assembling, ensure piston swings freely.
5. Set piston rings as shown in Fig. 38.