Engine Block Disassemble

1995 Saturn DOHC Engine Rebuild 400+/pics by SATURNFAN Canyon

ehunter1 Start with Crank bearings to top caps

ehunter1 Top crank caps and torqueing

ehunter1 Rod to piston work

ehunter1 Saturn 1996 SL2 DOHC - Putting rings on pistons

Tools Required
• J 41742 Connecting Rod Guide
• SA91101NE Feeler Gage Set
• SA9123E Gasket Seal Cutter
• SA9179NE Dial Indicator

Engine Preparation For Disassembly

Notice

Large washers or spacers with a 19.05 mm (3/4 in) inside diameter are required around the cylinder block dowel pin locators to prevent pin damage when attaching the engine to a stand. The cylinder block bolt threads are M12 x 1.75.

1. Mount the engine on a stand.
2. Remove all accessories and components:
• Starter
• Generator
• Water pump
• Oil pressure sending unit
• Knock sensor
• Crankshaft position sensor
• Flexplate or clutch assembly and flywheel
• Oil pan and filter

• Important

  Use the SA9123E to cut the oil pan seal away from the front cover and rear seal carrier.

  Oil pick-up tube
• Crankshaft bearing tie plate, DOHC LL0 engine only.

Cylinder Block Disassembly

1. Remove rear oil seal carrier.
Remove the four bolts and rear oil seal carrier. Pry tangs are located on both sides of the rear seal carrier. A rolling head pry bar or pinch bar will separate the carrier from the cylinder block, use care not to damage the sealing surface.



2. Check connecting rod side clearance vertically along side the rod:
Using a SA9179NE or equivalent or a SA91101NE or equivalent, measure the side clearance while moving the rod back and forth.
Side Clearance
• Standard: 0.165-0.435 mm (0.0065-0.01713 in)
• Service Limit: 0.470 mm (0.0185 in) max.

Important

Connecting rods and caps are identified with a serial number during manufacture to prevent interchanging of parts.

3. Remove connecting rod caps and check oil clearance.





Important

Do not pull the piston assembly down through the cylinder bore beyond its normal travel. The oil control rings can lodge between the bottom of the cylinder liner and machined step in block, and act as a snap ring, holding the piston firmly in place. Cylinder liner removal is required to free the piston.

Important

Keep the lower bearing inserted in the connecting rod cap.

4. Remove the connecting rod caps.





Important

Do not remove the connecting rod and piston assembly until all measurements are taken and the cylinder ridge has been removed, if present.

5. Install the J 41742 to protect the crankshaft from damage during piston and connecting rod assembly removal.




6. Clean rod journal and bearing.

Important

If the crank pin, connecting journal, or bearings are damaged, replace the bearings. If necessary, grind the connecting rod journals or replace the crankshaft. 0.25 mm (0.01 in) undersized crankshaft bearings are available for crankshaft repair.

7. Check the crank pin and bearing for pitting and scratches.





Important

The connecting rod bolts are torque-to-yield fasteners. It is acceptable to use the original rod bolts when using Plastigage® , or equivalent to determine crankshaft pin clearance. New bolts, which have never been tightened, must be used when the connecting rod and rod cap are final assembled in the engine.

8. Lay a strip of Plastigage®, or equivalent across the rod journal.





Important

Do not turn the crankshaft when there is a Plastigage®, or equivalent strip between the bearing and crankshaft journal.

9. Install connecting rod cap.
Tighten

Tighten the connecting rod cap-to-rod to 25 N·m (19 lb ft)+75 degrees.





10. Remove the connecting rod cap.
11. Measure the Plastigage®, or equivalent at its widest point.
Rod Journal Oil Clearance
• Standard: 0.003-0.053 mm (0.0001-0.0021 in)
• Service Limit: 0.055 mm (0.0022 in) max. If the oil clearance is greater than maximum, replace the bearings. If necessary, grind the connecting rod journals or replace the crankshaft.




12. Completely remove the Plastigage®, or equivalent.





Important

There are three bearing sizes available, (standard, 0.012 mm (0.0005 in), and 0.025 mm (0.001 in) to adjust fro correct connecting rod bearing oil clearance. 0.25 mm (0.01 in) undersized bearings are available for crankshaft repair.

Important

Do not pull the piston assembly down through the cylinder bore beyond its normal travel. The oil control rings can lodge between the bottom of the cylinder liner and machined step in block, and act as a snap ring, holding the piston firmly in place. Cylinder liner removal is required to free the piston.

13. Complete the procedure on the rest of the bearings.
14. Remove piston and connecting rod assemblies. Do not pull the pistons down through the cylinder bore beyond their normal travel.

Notice

When removing a ridge in the cylinder, do not damage the top of a cylinder bore.

15. If a ridge can be felt at the top of the cylinder bore, it must be removed. If necessary, install cylinder ridge reamer and remove the ridge at the top of the bore per the manufacturer's instructions.




16. Make sure the J 41742 are installed to protect the crankshaft from damage.
17. Push out the piston and connecting rod assembly through the top of the cylinder bore.





Important

Keep the bearing inserts with the connecting rod and cap. Arrange the piston and connecting rod assemblies in order.

18. Keep the bearing inserts with the connecting rod and cap.




19. Check crankshaft thrust clearance:
Using a dial indicator SA9179NE or equivalent, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Thrust Clearance
• Standard: 0.05-0.2 mm (0.002-0.0089 in)
• Service Limit: 0.25 mm (0.0098 in) max. If the clearance is greater than maximum, replace the thrust bearing.




20. Uniformly loosen and remove main bearing cap bolts.





Important

Keep the lower bearing inserted with the cap. Arrange the caps in correct order according to the number and arrow stamped on each cap.

21. Using the main bearing cap bolts, move the cap back and forth, to loosen and remove the cap and bearing. Bolts can be tapped lightly with a plastic hammer.





Important

If the journal or bearing is damaged, the bearing will require replacement. The crankshaft journals can be reground. 0.25 mm (0.01 in) undersized bearings are available for crankshaft repair.

22. Check each journal and bearing for pitting and scratches.




23. Lay a strip of Plastigage®, or equivalent across each journal.





Important

Do not turn the crankshaft.

24. Install main bearing caps.
Tighten

Tighten the crankshaft bearing cap-to-block to 50 N·m (37 lb ft).






Important

There are three bearing sizes available, standard, 0.012 mm (0.0005 in) and 0.02  mm (0.001 in) available to adjust for correct main bearing journal oil clearance. 0.25 mm (0.01 in) undersized bearings are available for crankshaft repair.

25. Remove main bearing caps.
26. Measure the Plastigage®, or equivalent at its widest point.
Oil Clearance
• Standard: 0.006-0.05 mm (0.0002-0.002 in) No. 1, 2, 3, 4, and 5
• Service Limit: 0.06 mm (0.0024 in) max. If the oil clearance is greater than maximum, replace the bearings. If necessary, grind the main bearing journals or replace the crankshaft.
27. Completely remove all Plastigage®, or equivalent material.




28. Remove the crankshaft:

Important

Arrange caps and bearings in correct order according to the number and arrow stamped on each cap.

29. Lift out crankshaft and remove upper bearings.