Reassemble
NOTE: All instructions, unless otherwise stated, apply to both RH A bank and LH B bank cylinder head assemblies.REASSEMBLE
CAUTION: Be sure that all components are scrupulously clean, blow out ALL oil galleries in crankshaft, camshafts, block, etc. with dry clean compressed air.
Smear the shoulders of cylinder liners with Hylomar and fit them into cylinder block. Remove any excess sealant.
NOTE: Cylinder liners must be fitted dry.
Be sure the liners are correctly seated and fit retaining tools JD 41.
NOTE: Early and late rear main seals:
Early - Up to Engine # 8S-66782 uses two piece rope seal.
Late - From Engine # 8S-66783 uses one piece seal.
If engine has Late type seal, skip down to ^^ and continue.
Early Rope Seal Procedure
Fit a new crankshaft rear oil seal, applying one drop of red Hermatite (or similar) into both sealing grooves, top and bottom, before fitting the seal halves into the grooves.
Fit the main bearing casting to the cylinder block and tighten the retaining nuts.
Sizing Rope-style Rear Main Seal:
Pre-size the rear oil seal using Service Tool JD 17B together with adaptor JD 17B-1.
Remove the rear main bearing casting.
^^
Liberally oil the upper main bearing shells and fit to the cylinder block.
Smear the rear oil seal with Dag Colloidal Graphite.
CAUTION: Centre and rear main bearing shells must not be confused with each other; the rear main bearing shell has an oil groove whereas the center main bearing shell is plain.
Position the crankshaft in the cylinder block.
Fit new bearing shells to the main caps; fit the caps, using pillar nuts as noted.
Fit and torque tighten the securing nuts.
Thrust Washers:
Check the crankshaft end float. The end float must be:
O.004-O.O06in (0.10-0.15 mm).
If the end float is outside these limits, renew the crankshaft thrust washers. If end float remains outside the limits subsequent to fitting the correct thickness washers 0.101-0.103 in (2.57-2.62 mm), the crankshaft must be renewed.
Fit the selected washers to the groove in the cylinder block.
NOTE: The grooved side of the thrust washers must face outwards.
Fit new bearing shells to the caps, oil the shells and crankshaft journals.
Smear the rope type oil seals in the rear main bearing casting with clean engine oil before assembly.
Fit the main bearing caps and nuts.
NOTE: Be sure that the reference marks on the bearing caps face the marks on the cylinder block.
Torque tighten the bearing caps one at a time, working from the center outwards.
Rear Main Seal - New Type:
Using suitable pressure injection equipment, inject Hylosil 102 (or equivalent) into the seal grooves (1) on each side of the casting (upper arrows). Stop injecting when sealant can be seen at the casting lower edges (lower arrows).
Clean the surface of the crankshaft and be sure it is smooth and free of damage. Lubricate the surface with clean engine oil.
Fit the new seal (EBC 2101), squarely onto the crankshaft using the guide supplied with the seal.
NOTE: The seal guide must not be separated from the seal prior to fitment or it will be rendered unsuitable for use.
Fitting Screws:
Fit the tool body onto the crankshaft to abut the seal rear face. Align the holes through the tool body with the threaded ones in the crankshaft flange, insert both bolt assemblies and screw them in until the bolt bottoms. Remove the seal guide.
Tighten the nuts/washers alternately against the tool face, 1/2 turn at a time, until the seal casing is driven into its location in the crankcase by the front rim of the tool.
Unscrew and remove the bolt assemblies, remove the body of the tool from the crankshaft.
Liberally smear the bore of number one cylinder with clean engine oil.
Ring Gap Spacing:
Be sure that the piston ring gaps of number one piston are evenly spaced around the circumference of the piston.
Smear the piston rings with oil and compress with suitable ring compressor.
Rod Bearing:
Fit the big end bearing shell to the connecting rod and bearing cap (2,3), be sure that the tabs on the shells are correctly located (1).
Oil bearing shell.
Fit protective covers (old spark plug wire boot) to connecting rod bolts prior to fitting to bore.
Enter the piston/connecting rod assembly into the top of bore, ensuring that FRONT stamped on piston faces forward. DO NOT use undue force when fitting the piston. Be sure the crankshaft journal is positioned correctly to allow rod bolts to clear when fitting.
Oil the shells and crankshaft journal, fit the bearing cap ensuring that it is the correct way round.
Fit and torque tighten the nuts.
Repeat the procedure for the remaining pistons.
Check that the engine rotates freely.
Fit oil pump drive gear to crankshaft.
Refit the oil pump to the drive gear, fit and tighten the securing nuts. Use new O-ring seals at both ends of the oil delivery pipe.
Locate the crankshaft undershield on the pillar nuts and place the oil delivery pipe into position.
Loosely secure the undershield and delivery pipe using two set screws/serrated washers. Use a new O-ring seal at the suction elbow and locate the suction pipe.
Secure the suction pipe clips and bracket using four set screws/serrated washers.
Fully tighten all six set screws securing the undershield.
Drive Plate:
Refit the drive plate to the crankshaft; be sure that the dowels are located correctly (2). Use a new locking plate.
Fit and tighten the securing bolts (1).
Refit the crankshaft sprocket.
Guide Alignment Tool:
If the timing chain guides are being renewed, special tool JD38 is required to correctly set guides. Refer to TIMING CHAIN DAMPERS.
Sprocket Retaining Tool:
Refit the timing chain tensioner (2) ensuring that it is fully retracted. Smear the journals of the jackshaft with clean engine oil and fit the jackshaft.
Refit the jackshaft locking plate.
Reposition the camshaft sprockets using retaining tools JD 40 (4).
Setting TDC #1:
Attach a dial gauge to number one A bank cylinder head stud.
Rotate the crankshaft, and using the dial gauge, set number one A piston at TDC.
Refit the jackshaft sprocket and timing chain, ensuring equal amount either side of the crankshaft sprocket and jackshaft.
Be sure that the center punch marks on the sprocket and jackshaft are 180 degrees apart and that the mark on the jackshaft is at the top.
Fit jackshaft retaining tool JD 39.
Tighten the bolts and lock over the tabs (1).
Remove jackshaft retaining tool JD 39.
CAUTION: The engine must on no account be rotated until the camshaft sprockets are coupled to the camshafts.
Refit the timing cover, use a new crankshaft oil seal and gaskets, tighten the bolts by diagonal selection.
Refit the crankshaft spacer. If necessary, renew the O-ring seal in the oil pump suction elbow.
Fit the sandwich plate to the crankcase, using a new gasket and secure using set screws/washers.
Secure the crankshaft angle indicator scale.
Fit the baffle plate to the sandwich plate.
Fit the oil sump pan, securing the oil cooler pipe bracket as noted.
Fit the suction union elbow to the sandwich plate and secure. Use a new seal.
Remove cylinder liner retaining tools JD 41.
Smear the mating faces of the tappet block and cylinder head with Hylomar.
Refit the tappet block to the cylinder head, tighten the nuts/capscrews by diagonal selection working from the center outwards.
Refit the camshafts.
Refit the bearing caps ensuring that reference marks correspond, tighten nuts by diagonal selection working from center outwards.
Adjust the valve clearances.
Fit the cylinder head gasket with TOP uppermost. Do not use jointing compound or grease.
Cam Gear Components:
Turn each camshaft until valve timing gauge C 3993 can be fitted to the slot in the front flange (4).
Refit the cylinder heads.
Fig. 5 Cylinder Head Bolt Tightening Sequence:
Torque tighten the nuts in the correct sequence.
Reconnect the camshaft oil feed pipes.
Remove retaining tools JD 40.
Remove the circlip retaining the camshaft sprocket couplings (2), press the sprocket on to the camshaft shoulder.
Rotate the coupling until two bolt holes align with holes in the camshaft.
Refit the couplings to the camshaft sprockets, refit the circlips, remove gauge C 3993.
Fit and tighten the securing bolts/tab washers, lock over the tabs (5).
Insert screwdriver tool JD 50-2 through the hole in the timing cover and release the chain tensioner locking catch; refit the rubber grommet.
Rotate the engine until the remaining bolt holes in the coupling are visible. Fit the remaining bolts, secure all bolts with tabwashers.
Apply sealant to the radial edge of a new half moon seal. Fit the seal to the carrier.
Fit new camshaft cover gaskets.
Refit the camshaft cover, fit and torque tighten the securing bolts.
Refit the jackshaft cover.
Refit the alternator and bracket.
Refit the distributor and amplifier unit.
Refit the water pump (using a new gasket) and engine cross pipe.
Water Pump And Crosspipe:
Refit the water inlet pipe to the water pump.
Crankshaft Pulleys:
Fit a new Woodruff key (4) to the crankshaft.
Refit the damper cone (3).
Refit the crankshaft damper (5) and pulley (6).
Fit and tighten the securing bolts (1,2).
Refit the starter motor.
Refit the transmission oil cooler pipes to the engine. Refit the air pump mounting bracket and adjustment link.
Refit the air pump.
Refit the compressor mounting bracket and compressor.
Refit the P/S pump mounting bracket and adjustment link.
Refit the P/S pump.
Refit the fan idler pulley assembly. Tension the fan belt.
Reconnect the oil cooler suction pipe union.
Refit the filter head to the cylinder block.
Refit the bypass valve union to the sandwich plate.
Refit the oil filter element/cartridge.
Reconnect the oil cooler feed pipe union.
Reconnect the oil pressure relief valve bleed pipe to the top of the sandwich plate.
Refit the torque converter to transmission.
Refit the transmission.
Refit the exhaust manifolds.
Refit the induction manifolds.
Refit engine/transmission assembly. Refer to ENGINE / REFIT.
SERVICE TOOLS
Engine Support Tool MS 53B
Timing Gauge C3993
Oil Seal Pre-sizing Tool JD 17B
Pre-sizing Tool Adaptor JD 1781
Jackshaft Retainer Tool JD 39
Camshaft Sprocket Retainer JD 40
Cylinder Liner Retaining Brackets JD 41
Timing Chain Tensioner Retainer and Release Tool JD5O