Cylinder Block Assembly

TOOLS REQUIRED: 

• J41742-SAT2 Connecting Rod Guide
• J44057 Crankshaft Tie Plate Socket
• SA9142E Piston Ring Compressor

1. Install dowel pins using a brass driver.
   Fig 1: Install Dowel Pins

   Courtesy of GENERAL MOTORS CORP.
   NOTE: Install the bearings with the oil holes in the block. The bearings with no holes must go in the main bearing caps.
2. Install main bearings:
   1. Install the bearings in the cylinder block and bearing caps.
      NOTE: Inspect alignment of bearing oil hole to the block bulkhead oil feed hole. At least 50 percent of the feed hole must be open/exposed.
      Fig 2: Install Main Bearings

      Courtesy of GENERAL MOTORS CORP.
3. Install the thrust bearing in number three upper main bearing position of the block.
4. Place crankshaft in cylinder block and coat with engine oil.
5. Install main bearing caps.
   NOTE: Bearing caps are numbered 1-5 and have an arrow that points toward the front of the engine. No. 1 cap is at the front of the cylinder block.
   1. Install the bearing caps in their proper locations. The arrow on the bearing cap points toward front of the cylinder block.
      Fig 3: Install The Bearing Caps In Their Proper Locations

      Courtesy of GENERAL MOTORS CORP.
      NOTE: Use a rubber mallet and rap the crankshaft rearward, and forward in the cylinder block to make sure the thrust bearing is properly aligned.
   2. Using a rubber mallet, rap the crankshaft rearward, then forward in the cylinder block to align the thrust bearing.
      Fig 4: Properly Aligning Thrust Bearing

      Courtesy of GENERAL MOTORS CORP.
   3. Apply a light coat of engine oil on the threads and under the heads of the cap bolts.
   4. Install and uniformly tighten the 10 cap bolts in several passes, in the sequence shown.
      Fig 5: Cap Bolt Tightening Sequence Diagram

      Courtesy of GENERAL MOTORS CORP.

      Torque: Crankshaft Bearing Cap-to-Block: 50 N.m (37 ft. lbs.) 

   5. Check that the crankshaft turns smoothly.
   6. Check the crankshaft thrust clearance.

      Thrust Clearance 

      Standard: 0.050 - 0.200 mm (0.0020 - 0.0089 in.) 

      Service Limit: 0.25 mm (0.0098 in.) max. 

      Fig 6: Crankshaft Thrust Clearance

      Courtesy of GENERAL MOTORS CORP.

      If the clearance is greater than maximum, replace the thrust bearing.

      NOTE: If the crankshaft does not turn smoothly, remove the bearing caps one at a time until the tight bearing is found. Check crankshaft journal dimensions and replace bearings (upper and lower) as necessary.
      NOTE: If a new crankshaft is installed, the PCM will be required to learn the reluctor ring notch location of the new crankshaft. Refer to CRANKSHAFT POSITION SENSOR SYSTEM VARIATION LEARN PROCEDURE .
      NOTE: Do not pull pistons down through the cylinder bores beyond their normal travel.
6. Install piston and connecting rod assemblies:
   1. Install Connecting Rod Guide J41742-SAT2 to connecting rod bolt holes. The guides are required to prevent damage to the crankshaft rod journals. Install the upper connecting rod bearings and coat with oil, if not completed previously.
      Fig 7: Install Connecting Rod Guide J41742-SAT2 To Connecting Rod Bolt Holes

      Courtesy of GENERAL MOTORS CORP.
   2. Using the Piston Ring Compressor SA9142E service tool, push the correct piston and connecting rod assembly into each cylinder with the two eyebrow cuts on the piston facing toward the intake manifold side of engine block.
      Fig 8: Push The Correct Piston And Connecting Rod Assembly Into Each Cylinder

      Courtesy of GENERAL MOTORS CORP.
   3. Verify proper piston pin orientations by looking at underside of pistons. Ensure piston pin boss with the rectangular-shape casting feature is pointing toward back of engine.
      Fig 9: Verify Proper Piston Pin Orientations

      Courtesy of GENERAL MOTORS CORP.
      NOTE: The powdered metal connecting rod and cap are machined for the proper clearances. The connecting rod and cap must be used as an assembly with no repair or modifications to either mating surface.

      Do not attempt to repair the connecting rod or the cap mating surfaces. If service is required, the connecting rod and cap must be replaced as an assembly.

      NOTE: Use extreme care when installing the piston and connecting rod. The connecting rod must be properly aligned with the crank pin to prevent journal damage. It is standard practice to assemble the piston and connecting rod with bearing tang slots in the rod directed toward the exhaust manifold side.
7. Install connecting rod caps:
   Fig 10: Install Connecting Rod Caps

   Courtesy of GENERAL MOTORS CORP.
   NOTE: Connecting rods and rod caps which are assembled properly will have matching serial numbers located as illustrated.

   Fig 11: Connecting Rod Serial Number Location

   Courtesy of GENERAL MOTORS CORP.

   The large end of the connecting rod will have machined surfaces that appear as illustrated when properly assembled.

   Fig 12: Assembling Connecting Rods

   Courtesy of GENERAL MOTORS CORP.
   1. Match the serial number of the cap with the serial number of the connecting rod.
      NOTE: The cap and rod tangs are located on the same side of the connecting rod bore.
   2. Install the lower connecting rod bearing in the cap. Apply a light coat of oil on the bearing surface.
      NOTE: The machined slots in the rod and cap must be properly aligned to prevent bearing damage.
   3. Install the cap with the bearing tang slots in the cap and connecting rod facing each other.
      Fig 13: Installing Connecting Rods

      Courtesy of GENERAL MOTORS CORP.
      NOTE: The connecting rod bolts are torque-to-yield fasteners. The number of times the bolts can be used is limited. New bolts, which have never been tightened, must be used when the connecting rod and rod cap are final assembled in the engine.
   4. Install and alternately tighten the cap bolts in several passes.

      Torque: Connecting Rod Cap-to-Rod: 25 N.m (19 ft. lbs.) + 75° 

      Fig 14: Installing Cap Bolts

      Courtesy of GENERAL MOTORS CORP.
   5. Check that the crankshaft turns smoothly.
      NOTE: Check the oil seal lip contact surface of the crankshaft for scratches or damage. If rust is present, remove with a Scotch-Brite® pad or equivalent. Do not use emery cloth, sandpaper or other abrasive materials. Rust removal is necessary to prevent seal lip damage during installation.
   6. Check the connecting rod side clearance.

      Side Clearance 

      Standard: 0.165-0.435 mm (0.0065-0.1713 in.) 

      Service Limit: 0.470 mm (0.1850 in.) max. 

      If clearance is less or greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

      PISTON PROTRUSION BELOW DECK OF BLOCK 

      1. Standard: 0.066 mm (0.0026 in.) max. 
      2. Service Limit: 0.145 mm (0.0057 in.) max. 

      PISTON PROTRUSION ABOVE DECK OF BLOCK 

      1. Standard: 0.300 mm (0.0118 in.) max. 
      2. Service Limit: 0.379 mm (0.0149 in.) max. 

8. Install rear oil seal assembly if required:
   1. Make sure surface is free of RTV and clean with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol Saturn P/N 21007432 (or equivalent).
      NOTE: Assemble while RTV is still wet (within three minutes). Do not wait for the RTV to skin over.
   2. Install a 5.0 mm (.200 in.) diameter bead of RTV on the rear seal carrier.
      Fig 15: Applying RTV To Rear Seal Carrier

      Courtesy of GENERAL MOTORS CORP.
9. Install the four rear crankshaft seal assembly bolts.

   Torque: Crankshaft Rear Oil Seal Assembly-to-Block: 11 N.m (97 in. lbs.) 

   NOTE: Check components for debris. Clean all parts before installation.
10. Refer to the appropriate SOHC or DOHC cylinder head procedures in this article for cylinder head and front cover installation.
    NOTE: Prior to assembly to the engine, tie-plate inserts must be rotated counterclockwise to recess the inserts within the tie plate. Failure to follow this procedure could result in tie-plate fracture and could cause engine damage.
    NOTE: The tie-plate is assembled to the engine with the large rectangular opening located at rear of engine.

    Fig 16: Tie-Plate

    Courtesy of GENERAL MOTORS CORP.
11. Install crankshaft bearing tie plate (DOHC [LLO]) and oil pickup tube with a new O-ring.
    1. Install crankshaft bearing tie-plate over main bearing cap studs.
    2. Install six crankshaft bearing tie-plate fasteners to the oil pan rail on the engine block.

       Torque: 

       Crankshaft Bearing Tie Plate-to-Oil Pan Rail: 55 N.m (41 ft. lbs.) 

       Tie Plate to oil pan rail torque sequence:

       Fig 17: Tie Plate To Oil Pan Rail Torque Sequence Diagram

       Courtesy of GENERAL MOTORS CORP.
       NOTE: Replace tie-plate washers with new washers when assembling tie-plate to engine.
    3. Install tie-plate inserts. Rotate inserts clockwise to bring inserts into contact with bearing cap studs. Use Crankshaft Tie Plate Socket J44057.

       Torque: 

       Crankshaft Bearing Tie Plate Insert: 3.5 N.m (31 in. lbs.) 

       Tie Plate Insert torque sequence:

       Fig 18: Tie Plate Insert Torque Sequence Diagram

       Courtesy of GENERAL MOTORS CORP.
    4. Install washers over bearing cap studs onto inserts.
    5. Install ten nuts to bearing cap studs.

       Torque: 

       Crankshaft Bearing Tie Plate: 25 N.m (18 ft. lbs.) 

       Fig 19: Installing Bearing Cap Studs

       Courtesy of GENERAL MOTORS CORP.

       Bearing Cap Stud Torque sequence:

       Fig 20: Bearing Cap Stud Torque Sequence Diagram

       Courtesy of GENERAL MOTORS CORP.
       Fig 21: Installing Tie-Plate

       Courtesy of GENERAL MOTORS CORP.
    6. Install oil pickup tube.

       Torque: Oil Pickup Tube-to-Block: 15 N.m (11 ft. lbs.) 

       Torque: Oil Pickup Tube Bracket-to-Tie Plate: 15 N.m (11 ft. lbs.) 

    NOTE: The oil pan is easier to install after front cover assembly installation.
12. Install the oil pan assembly and fasteners.
    1. Make sure the oil pan surface is free of cured RTV and cleaned with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol Saturn P/N 21007432 (or equivalent).
       NOTE: Assemble while the RTV is still wet (within three minutes.) Do not wait for the RTV to skin over.
    2. Apply a 4.0 mm (0.160 in.) bead of RTV in the oil pan groove, routing the RTV bead toward the inside of all bolt holes.

       Torque: Oil Pan-to-Block: 9 N.m (80 in. lbs.) 

       Fig 22: Applying RTV To Oil Pan

       Courtesy of GENERAL MOTORS CORP.
13. Install water pump:

    Install a new gasket. Use a small amount of RTV in three or four spots around the outer bolt holes to hold the gasket in place. Refer to the COOLING SYSTEM - REMOVAL & INSTALLATION for water pump installation.

    Torque: 

    Water Pump-to-Block: 30 N.m (22 ft. lbs.) 

    Water Pump Pulley-to-Water Pump Hub: 25 N.m (19 ft. lbs.) 

14. Install dipstick tube with a new O-ring. Lubricate O-ring with engine oil and install into the cylinder block. Attach tube bracket to cylinder block.

    Torque: Oil Level Indicator Tube-to-Block: 30 N.m (22 ft. lbs.) 

    Fig 23: Install Dipstick Tube With A New O-Ring

    Courtesy of GENERAL MOTORS CORP.
15. Install the flexplate or flywheel. The flexplate and flywheel can be installed at any bolt hole location. The flexplate or flywheel can be held with a flywheel turning tool when torquing the bolts.
    Fig 24: Install The Flexplate Or Flywheel

    Courtesy of GENERAL MOTORS CORP.
    • Flexplate to crankshaft

      Torque: Flexplate-to-Crankshaft: 60 N.m (44 ft. lbs.) 

    • Flywheel to crankshaft

      Torque: Flywheel-to-Crankshaft: 80 N.m (59 ft. lbs.) 

16. Install the following accessories:
    • Knock sensor

      Torque: Knock Sensor: 25 N.m (19 ft. lbs.) 

    • Crankshaft position sensor. Lubricate O-ring with oil before installation.

      Torque: Crankshaft Position Sensor: 9 N.m (80 in. lbs.) 

    • Starter motor to block.

      Torque: Starter Motor-to-Block: 37 N.m (27 ft. lbs.) 

      NOTE: Whenever the cylinder block has been disassembled or the oil pump is removed, fill the oil cavity under the oil filter with clean engine oil to prime the pump. The oil pump must also be packed with petroleum jelly as outlined in the Lubrication System section.
    • Generator

      Torque: Generator Bolts: 32 N.m (24 ft. lbs.) 

    • Oil Filter

      Torque: Gasket contact and 3/4 to 1 turn 

    • Oil pan drain plug

      Torque: Oil Pan Drain Plug: 37 N.m (27 ft. lbs.) 

    • Oil pressure sending unit

      Torque: Oil Pressure Sending Unit: 45 N.m (33 ft. lbs.)