Later these procedures Testament cause an engine that Testament be every bit as commendable as current, as elongate as you don't share any short cuts. This is not an expensive proposition when compared to the obtain of a distinct or used engine. Equal care for in faculty that the torques and clearances are actual substantial to a experienced extreme decision.
Instructions
1. Remove the rod-bearing cap and install the bearings in both halves. Lubricate the bearings with STP and insert the pistons into the block, with the notch on the top of the piston facing forward. Push the pistons down and install the rod cap and torque it to specifications. Do the same for the remainder of the pistons.
Remember to turn the engine over for at least 20 seconds without letting it start to prime the oil pump. Remove the timing belt. Remove the oil pan. Remove the valve cover.
3. Remove the head bolts and remove the head assembly. Remove the balance-shaft tensioner and the belt. Then carefully extract the balance shaft. Remove the oil pump. Remove the piston-rod caps one at a time and push the piston out of the chamber. Replace the rod end cap and loosely tighten the nuts.
4. Remove the crankshaft bearing caps and lift the crankshaft out of the block. Replace the bearing caps in their original position and loosely tighten the bolts. Remove the camshaft bearing caps and remove the camshaft. Replace the caps in their original position and loosely tighten the bolts.
5. Take the block, crank, pistons and head to the machine shop. Tell them to hot-tank the block to clean it inside and bore it .30 oversized. Have them install new freeze plugs and balance-shaft bearings. Have the head checked for cracks in the surface, and if it checks out OK, have them do a valve job. You will need new pistons and rings--have the machine shop press the pistons on the rods. They should also check the crankshaft for size and supply the right-sized main and rod bearings. The last thing is to have them write down the recommended torques for the main bearings, rod bearings and head bolts, based upon that year of engine.
6. Wash out the block with a water hose and dishwashing soap to get all of the filings out. Blow off the block with an air gun and spray the lifter valleys with a silicone lubricant.
7. Turn the block upside down and install the main bearing halves into the block. Lubricate with STP oil treatment. Wipe the crank down thoroughly and lay it into the block. Install the upper halves of the main bearings and torque to specifications.
8. Using the ring expander or installer, install the rings with a minimum of 90 degrees between gaps. Use STP oil treatment to lightly lubricate the cylinder walls. Pour some oil over the rings and install the ring compressor. Remove the embellishment operate belts and the tensioner pulley and bracket. Remove the water-pump pulley and the power-steering pulley and pump. Remove the crankshaft pulley bolts and the crankshaft pulley. Remove the upper and lower timing-belt covers.
9. Clean the top of the block and the cylinder head to make sure there are no foreign particles on them. Install the head gasket; carefully and slowly line up and lay the head on the block. Oil the threads of the head bolts and install them. Torque the head bolts to specifications, starting in the center of the head. Using an X pattern, move from the middle to the closest upper right to the lowest left, and so on. Keep tightening the bolts, moving outward. Tighten the bolts in three stages of 30, then 60 and finally the required torque you were provided by the machine shop.
10. Lubricate the lands on the head for the camshaft with STP. Install the camshaft and the caps and torque to the required torque. Lubricate the balance-shaft lobes with STP and carefully install the shaft. Do not force it; simple feel for the holes in the block and insert it slowly.
11. Install the oil pump and its sprocket. Install the oil pan. Make sure the crankshaft sprocket notch is lined up with the arrow on the block. Install the balance-shaft tensioner; move it to the left and loosely tighten the bolt. Install the balance-shaft belt, starting from the right and working counterclockwise, keeping the tension on the non-tensioned side. Make sure the balance-shaft sprocket triangle mark lines up with the corresponding mark on the block. Loosen the bolt on the tensioner, pry it toward the belt to apply tension and tighten the bolt to 15 foot-pounds of torque.
12. Install the camshaft tensioner, move it toward the water pump and loosely tighten the bolts. Make sure the crankshaft mark is aligned and the oil pump notch is lined up with its mark on the block. Make sure the camshaft mark on the sprocket is lined up with the lower mating surface of the cylinder head at the 9 o'clock position.
13. Install the timing belt in a counterclockwise, manner starting with the right side at the crank sprocket, over the oil pump, over the camshaft sprocket and down on the inside of the tensioner. Keep the tension on the right side. Loosen the tensioner bolts.
14. Turn the crankshaft clockwise two turns and realign the timing marks. It is important to tighten the lower bolt of the tensioner first, and then the top nut. Install the timing-belt covers, the crankshaft pulley and the bolts to the outer pulley, and torque the center bolt to 94 foot-pounds of torque.
15. Install the valve cover. Install the rear main seal.2. Turn the crankshaft clockwise until the notch on the crankshaft sprocket is lined up with the arrow on the block. Loosen the tensioner nut and bolt and remove the tensioner.
