Engine Assembly

Ensure all engine components are thoroughly cleaned prior to assembly. Lubricate all mating surfaces with clean engine oil. During assembly ensure all gaps and end plays are accurate.
1. Install piston onto connecting rod. Lubricate piston pin with clean engine oil.
2. Using an arbor press, press piston pin into piston. Pressing load is 1,100-3,300 lbs. (500-1500 kg). If pressing load is other than specified limit, replace piston pin or connecting rod.
3. Install oil ring upper and lower plates and the spacer onto piston. Install compression rings, making sure ``R'' marks face upward.

Fig. 8 Positioning piston rings onto piston:

4. Set open end of each ring in the position shown in Fig. 8.
5. Install crankshaft and pistons into cylinder block. Make sure F marks stamped on pistons face toward crankshaft pulley.
6. Install the crankshaft thrust washer into cylinder block, with groove facing outward.
7. Using Plastigage, measure oil clearance between crankshaft journal and main bearing. Clearance limit should be .0031 inch (.08 mm). If clearance exceeds specified limit, grind the crankshaft and use an undersize bearing. Note the following:

Under Size Finished Size
.010 inch, 1.9528-1.9534 inch,
(.25 mm) (49.6-49.7 mm)
.020 inch, 1.9430-1.9436 inch,
(.50 mm) (49.4-49.5 mm)
.030 inch, 1.9332-1.9338 inch,
(.75 mm) (49.1-49.2 mm)

Match installation of main bearing caps with cap number and arrow mark shown on the bearing caps.

Fig. 9 Installing side seal:

8. Install side seal into cylinder block, making sure seal hole, Fig. 9, is facing either inside or outside of cylinder block.
9. Using a dial indicator, check crankshaft endplay. Endplay should be .0039-.0059 inch (.10-.15 mm). Endplay limit is .0118 inch (.30 mm). If endplay exceeds specified limit, use oversize washers and install onto crankshaft. The following oversize washers are available: .010 inch (.25 mm), .020 inch (.50 mm) and .030 inch (.75 mm).
10. Using Plastigage, check clearance between crank pin and connecting rod bearing as follows:
a. Install and torque connecting rod cap bolts to 22-25 ft.lbs. (30-35 N-m). When installing the connecting rod bearing cap onto the connecting rod, ensure mark on bearing cap aligns with mark on connecting rod
b. Measure clearance, which should not exceed .0039 inch (0.1 mm).
c. If clearance exceeds specified limit, grind crankshaft and use an undersize bearing. The following undersize bearings are available:

Under Size Finished Size
.010 inch, 1.5598-1.5604 inch,
(.25 mm) (39.690-39.706 mm)
.020 inch, 1.5500-1.5506 inch,
(.50 mm) (39.440-39.456 mm)
.030 inch, 1.5402-1.5408 inch,
(.75 mm) (39.190-39.206 mm)

11. Using a feeler gauge, measure connecting rod endplay. Endplay should be .012 inch (.3 mm).
12. Install timing chain as follows:
a. Install sprocket onto crankshaft, then install oil pump, pump sprocket and chain into cylinder block. Engage oil pump and crankshaft sprockets with chain.

Fig. 10 Aligning timing marks on timing chain and crankshaft sprocket with engine inverted:

b. Align crankshaft and camshaft sprocket timing marks with colored links on timing chain, Fig. 10.

Fig. 11 Securing timing chain and sprocket with engine inverted:

c. Using a piece of wire, tie the timing chain and camshaft sprocket to prevent movement, Fig. 11.
d. Using sealer No. 852777739 or equivalent, apply sealer onto oil pan flange and install onto engine. Wait approximately 30 minutes then torque oil pan bolts to 5-9 ft.lbs. (7-12 N-m).
e. Install timing chain cover gasket and timing chain cover onto engine. Cut off any excessive portion of the timing chain cover gasket from both ends of timing chain cover.
13. Install flywheel assembly onto crankshaft. Using tool No. 49E301060 or equivalent, lock flywheel and torque flywheel bolts to 60-65 ft.lbs. (81-89 N-m) on models with manual transaxle or 51-61 ft.lbs. (70-85 N-m) on models with automatic transaxle.
14. Using sealer No. 852777739 or equivalent, apply sealer onto crankshaft pulley bolt and torque bolt to 80-87 ft.lbs. (118-120 N-m).
15. Using tool Nos. 490636100A and 490221222A or equivalents, install valves into cylinder head.
16. Install valve rocker arms onto the rocker arm shaft. Ensure there is at least .039 inch (1 mm) of off-set between center of rocker arm adjusting screw and exhaust valve stem.

Fig. 2 Cylinder head bolt tightening sequence:

17. Install cylinder head and cylinder head bolts. Torque cylinder head bolts in sequence, Fig. 2. Torque bolts to 56-59 ft.lbs. (74-80 N-m).
18. Using Plastigage, measure oil clearance between camshaft and bearing cap. Oil clearance should be .0059 inch (.15 mm).
19. Using tool No. 49E301060 or equivalent, lock flywheel and torque camshaft sprocket nut to 51-58 ft.lbs. (70-79 N-m).
20. Check camshaft endplay (clearance between camshaft sprocket and thrust plate). Endplay should be .008 inch (.20 mm). If endplay exceeds specified limit, replace the thrust plate.
21. Install the chain tensioner into the timing chain cover as follows:

Fig. 12 Chain tensioner assembly:

a. Push sleeve completely into chain tensioner body and lock with pin, Fig. 12.
b. Install chain tensioner into timing chain cover. When the engine is cranked, the pin will unlock, forcing the sleeve outward, completing the timing chain adjustment.
22. Rotate crankshaft until No. 1 cylinder is at TDC of the compression stroke. Ensure mark on crankshaft aligns with mark (T) on the timing chain cover.

Fig. 13 Aligning distributor shaft notch with camshaft groove:

23. Using clean engine oil, lubricate distributor shaft O-ring. Turn and install distributor shaft onto camshaft. Ensure distributor shaft notch engages groove on camshaft, Fig. 13.

FINAL ASSEMBLY

1. Install thermostat and cover.
2. Install alternator.
3. Install oil filter and intake manifold.
4. Install water and fuel pumps.
5. Install exhaust manifold and fan pulley.