Cylinder Block Assembly: Service and Repair

DISASSEMBLY
Engine Block

Fig. 7 Engine outer components (Part 1 of 3):

Fig. 7 Engine outer components (Part 2 of 3):

Fig. 7 Engine outer components (Part 3 of 3):

Fig. 8 Main bearing cap bolt loosening sequence:

1. Remove engine outer components, Fig. 7.
2. Place engine on suitable work stand.
3. Drain coolant and engine oil.
4. Remove cylinder heads and timing chain. Refer to TIMING CHAIN, for repair procedure.
5. Remove oil pan. Refer to Oil Pan, Engine for replacement procedure.
6. Remove pistons.
7. Remove bearing beam, bearing caps and crankshaft, loosening attaching bolts in sequence, Fig. 8.

Piston and Rod Removal
1. Using ring remover, remove piston rings.
2. Using suitable tool, drive out pin.

ASSEMBLY

Fig. 9 Main bearings:

Fig. 10 Main bearing cap bolt tightening sequence:

1. Set main bearings in proper position on cylinder block and main bearing cap, Fig. 9.
2. Install crankshaft, main bearing caps and beam. Tighten main bearing bolts in sequence shown in Fig. 10, as follows:
a. Torque bolts to 24-28 ft. lbs.
b. Turn bolts an additional 45-50°; clockwise or if angle wrench is not available, Torque bolts to 54-61 ft.lbs.

3. Ensure crankshaft turns smoothly by hand.
4. Measure crankshaft endplay. Endplay should be 0.0039-0.0102 inch.
5. Install connecting rod and caps.
6. 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. Arrange so that front mark of piston head faces toward front of engine.

7. Install connecting rod bearing caps and torque connecting rod bearing nuts to 10-12 ft. lbs., then turn nuts an additional 60-65° clockwise or if angle wrench is not available, torque bolts to 28-33 ft. lbs.
8. Measure connecting rod side clearance. Clearance should be 0.0079-0.0138 inch.
9. If clearance is not within specifications, replace connecting rod and/or crankshaft.
10. Install rear oil seal retainer.

Fig. 15 Piston & rod assembly:

Fig. 16 Piston Ring Positioning.:

Fig. 15 Piston & rod assembly:

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. 15.
3. Piston skirt diameter (A) should be 3.3850-3.3854 inch standard piston, dimension (a) 0.433 inch.
4. After assembling, ensure piston swings freely.
5. Set piston rings as shown in Fig. 16. When piston rings are not replaced, ensure piston rings are mounted in their original positions. If piston rings are being replaced and no punch mark is present, rings can be mounted with either side up.