Cylinder Block Assembly: Service and Repair

DISASSEMBLY
Cylinder Block

Fig. 3 Engine Outer Components:

Fig. 4 Main bearing cap loosening sequence:

1. Remove engine as outlined under Engine then remove remaining outer components, Fig. 3.
2. Place engine on suitable work stand.
3. Drain coolant and engine oil.
4. Remove timing chain and cylinder head as outlined under Timing Chain.
5. Remove oil pan as outlined under Oil Pan, Engine.
6. Remove rod bearing caps, then remove pistons.
7. Remove main bearing caps, loosening in two or three stages, attaching bolts in sequence, Fig. 4, then lift out crankshaft.
8. Remove bearing shells from block and main bearing caps.

Piston and Rod Assembly
1. Using a suitable piston ring expander tool, remove piston rings.
2. Remove piston pin snap rings.
3. Heat piston and rod assembly to 140-158°F in a heated oil bath, or if heated oil bath is not available, place piston in a suitable piston pin press at room temperature.
4. Using a suitable driver push pin from piston and rod.

ASSEMBLY
Cylinder Block

Fig. 5 Main bearings:

1. Install main bearing in their proper positions on cylinder block and main bearing cap, Fig. 5.

Fig. 6 Main bearing cap tightening sequence:

Fig. 7 Main bearing cap tightening data:

2. Install crankshaft, main bearing caps and beam. Tighten bolts in sequence shown in Fig. 6. Tighten bolts to specifications in Fig. 7.
3. Measure crankshaft endplay. Endplay should be 0.0039-0.0102 inch.
4. Install connecting rod bearings on connecting rods. Ensure oil hole in rod and bearing match.
5. Install piston and rod assemblies, noting the following:
a. Piston skirt diameter (A) should be 3.6606-3.6610 inch standard piston, dimension (a) 0.453 inch.

Fig. 8 Piston dimensions:

Fig. 9 Piston ring gap spacing:

b. Set piston rings and ring gaps as shown in Fig. 8 and 9.

7. Install connecting rod bearing caps and torque nuts to 10-12 ft. lbs., then turn an additional 60-65° clockwise or torque to 28-33 ft. lbs.
8. Measure connecting rod side clearance. Clearance should be 0.0079-0.0138 inch.

Piston and Rod Assembly

Fig. 10 Piston & rod assembly:

1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 140-158°F in a heated oil bath, or if heated oil bath is not available, place piston in a suitable piston pin press at room temperature.
3. Align direction of piston and connecting rod. Ensure numbers stamped on connecting rod and cap correspond to each cylinder, Fig. 10.
4. Using a suitable driver assemble piston, pin and connecting rod, then install snap ring.
5. Install piston rings.