Engine Assembly

Cylinder Head Assembly

1. Coat new guides with oil and press into cylinder head from camshaft side as far as they will go.
2. Ream new guides to specifications using a hand reamer.
3. Insert valve in cylinder head and install valve stem seal using a suitable tool.
4. Install valve spring seat, valve springs and spring retainer. Compress valve springs and install locking collets.
5. Place cam followers or hydraulic lifters over valve springs and install camshaft.

Fig. 5 Camshaft bearing cap installation:

6. Lubricate camshaft bearing caps and journals and install bearing caps, noting off center bearing position, Fig. 5.

Fig. 10 Camshaft bearing cap removal:

7. First lightly tighten nuts of bearing caps 2 and 4, Fig. 10, diagonally, then tighten all nuts to 14 ft.lbs. on all 1984-87 models and 1988 5000 models and to 15 ft.lbs. on 1988 80/90 models.
8. Rotate camshaft until valve is fully closed, cam lobe pointing upward, and check clearance.
9. If clearance is not within specifications on models less hydraulic lifters, adjustment disc in top of cam follower will have to be replaced.
10. Depress cam follower using suitable tools and remove adjusting disc.
11. Measure disc and replace with one of the correct size to restore proper clearance.

Crankshaft & Cylinder Block Assembly

1. Install upper main bearings in cylinder block. Upper main bearings contain oil grooves, and thrust bearing is No. 4 from drive belt end of engine.
2. Lubricate crankshaft journals and upper main bearings with assembly lubricant and install crankshaft.
3. Install nongrooved lower main bearings into main bearing caps and lubricate bearings with assembly lubricant.
4. Install main bearing caps in correct order with reference number toward oil filter side of engine.
5. Torque main bearing cap bolts to specification evenly, working from center toward outside.
6. Check that crankshaft rotates smoothly and endplay is within specifications.
7. Install new seal in rear cover and install cover and seal assembly.
8. Align reference marks between flywheel and crankshaft and install flywheel.

Fig. 11 Flywheel installation.:

9. On automatic transmission models, notch on outer washer (1), Fig. 11, must face converter. Distance between drive plate must measure .677-.741 inch, and can be adjusted by thickness of shim (2), Fig. 11.
10. Install new seal in oil pump and install oil pump making sure crankshaft engages oil pump gears correctly.
11. Install oil pump pickup and oil pan, using new gaskets.
12. Insert piston pin through piston and connecting rod and secure with pin retainers.
13. Install piston rings using a ring expander. ``Top'' marking must face piston crown, recessed edge on outside of center ring must face piston pin.
14. Insert bearing half in connecting rod big end and lubricate bearing and crankshaft journal with assembly lubricant.

Fig. 12 Piston installation:

Fig. 13 Connecting rod installation marks:

15. Install piston/connecting rod combination with arrows on piston crown, Fig. 12, toward drive belt side and marks on connecting rod, Fig. 13, toward oil filter side of engine.
16. Insert bearing half in connecting rod cap, lubricate bearing, and install cap.
17. Torque connecting rod cap retaining nuts to specifications.
18. Install belt drive sprocket and crankshaft pulley, torquing bolt to 235 ft.lbs.

FINAL ASSEMBLY

Fig. 7 Crankshaft timing marks.:

Fig. 8 Camshaft timing marks.:

1. Align timing marks on camshaft and cylinder head, Fig. 8, and on flywheel and clutch housing, Fig. 7, before installing cylinder head.




2. Install cylinder head and torque bolts to specifications in sequence, Fig. 9.
3. Install water pump with bolts hand tight.
4. With timing marks aligned, install camshaft drive belt and adjust tension by rotating water pump clockwise. Tighten water pump bolts.
5. Belt is properly adjusted when it can be twisted 90°, by hand, in run between camshaft and water pump sprockets.
6. Reverse procedure to install remaining components.