Engine Assembly

Before assembling engine note the following:
1. Make sure all parts are clean before installation.
2. Apply new engine oil to all sliding and rotating parts.
3. Do not reuse gaskets or oil seals.
4. Check all critical clearances, endplays, and oil clearances.
5. Tighten critical fasteners to specified torques.
6. Replace any plain bearings that are damaged in any way.

CYLINDER HEAD ASSEMBLY

1. Apply engine oil to valve guides.
2. Using valve seal installer 49 S120 160, or equivalent, install valve seals.
3. Install valves as follows:
a. Install lower spring seat.
b. Coat valve stems with molybdenum disulphide grease. Insert valve.
c. Install valve spring and spring seat.
d. Using valve spring compressor 49 0636 100A and pivot 49 S120 222, or equivalents, compress valve spring and install valve keeper.
4. Install valve tappets and adjusting discs as follows:
a. Apply engine oil to tappet and insert in bore.
b. Insert adjusting discs.

PISTON & CONNECTING ROD

1. Assemble piston and connecting rod as follows:

Fig. 22 Piston & connecting rod alignment:

a. Align oil hole in big end of connecting rod with F mark on piston, Fig. 22.
b. Coat small end of connecting rod with motor oil.
c. Insert snap ring into one piston pin hole.
d. Heat piston to 122-167 degrees F and install connecting rod and piston pin. Install remaining snap ring.
2. Apply liberal coat of motor oil and install piston rings as follows:
a. Install in sequence, oil ring expander, oil ring, second ring, and top ring.

Fig. 23 Positioning piston rings:

b. Align ring gaps as shown in Fig. 23.
3. Install pistons and connecting rods as follows:
a. Install connecting rod bearing in connecting rod and apply coat of oil.
b. Clean inner surface of cylinder and apply coat of engine oil.
c. Using suitable piston installer, insert each piston and connecting rod into cylinder block with F mark on piston facing towards front of engine block.

CRANKSHAFT ASSEMBLY

1. Install oil jets in cylinder block and torque to 9-13 ft.lbs.
2. Make sure back surfaces of main bearings are clean and install.
3. Using Plastigage, check main bearing clearance. Torque main bearing cap bolts to 61-65 ft.lbs. Standard clearance is .0012-.0019 inch. Clearance must not exceed .0031 inch.
4. If clearances are excessive, replace bearings with new bearings and recheck.
5. If clearances are still excessive, crankshaft must be reground and undersize bearing installed.
6. Coat main bearings and journals with motor oil and set crankshaft in journals.
7. Apply motor oil to thrust bearing and install in center journal so oil groove faces toward crankshaft, Fig. 12.
8. Position main bearing cap, and push crankshaft forwards. Then pull crankshaft back, and torque main cap bolts to 61-65 ft.lbs.
9. Check endplay. Standard endplay is .0016-.0110 inch. Endplay must not exceed .0118 inch. Also check that crankshaft turns easily.
10. If endplay is not correct, replace thrust bearing. Standard size thrust bearing thickness is 0787-.0807 inch. Oversize thrust bearing thickness is .0858-.0878 inch. Replace rear thrust bearing first. If endplay is still not correct, replace front thrust bearing.
11. Coat outside of pilot bearing and pilot bearing bore with motor oil. Set suitable pipe against outer bearing race and tap pilot bearing into crankshaft.
12. Apply grease to pilot bearing.
13. Using Plastigage, check connecting rod bearing clearance. Standard clearance is .0012-.0024 inch. Clearance must not exceed .0031. Undersize bearings are available in .010, .020, and .030 inch sizes.
14. Measure connecting rod side clearance. Standard clearance is .0043-.0102 inch. Side clearance must not exceed .014 inch.
15. Apply motor oil to connecting rod bearing. Install connecting rod cap taking care to align connecting rod and cap mating marks, and torque to 51-54 ft.lbs.

REAR OIL SEAL RETAINER

1. Apply motor oil to oil seal and retainer.
2. Press oil seal into rear cover.

Fig. 11 Exploded view of oil pump, oil pan & flywheel assembly:

3. Install bearing retainer and gasket and torque to 5-7 ft.lbs., Fig. 11.

OIL PUMP BODY ASSEMBLY

1. Apply lithium base grease to O-ring, and position in oil pump body, Fig. 11.
2. Apply motor oil to oil seal lip.
3. Apply sealant to oil pump flange and install oil pump. Torque mounting bolts to 12-17 ft.lbs.

OIL PUMP PICKUP & PAN

1. Install oil pump pickup on oil pump body and torque bolts to 5-7 ft.lbs.
2. Trim rear oil seal retainer gasket flush with oil pan mounting flange. Take care not to scratch oil seal retainer.
3. Apply continuous .08-.16 inch thick bed of sealer to oil pan flange inside of bolt holes. If oil pan gasket is used, apply sealant only to seams where rear oil seal retainer and oil pump meet engine block.
4. Torque oil pan bolts to 5-7 ft.lbs.

END PLATE, FLYWHEEL & CLUTCH

1. Install end plate and torque bolts to 12-17 ft.lbs.
2. Install flywheel and apply sealant to bolts and torque to 130-137 ft.lbs.
3. Clean clutch disc and splines. Apply thin coat of molybdenum sulphide grease to splines.
4. Install clutch disc and cover using suitable aligning tool. Torque clutch cover bolts to 16-24 ft.lbs.

TIMING BELT CRANKSHAFT SPROCKET

1. Install timing belt sprocket with key and torque bolt to 116-123 ft.lbs.
2. Turn crankshaft so No. 1 cylinder is at TDC, then turn crankshaft about 45 degrees in clockwise direction.

CYLINDER HEAD INSTALLATION

1. Make sure engine block deck is free of dirt and grease.
2. Position new cylinder head gasket on block.
3. Position cylinder head on block.
4. Check that head bolt length from bellow head is 4.437-4.460 inches. Bolt must not be longer than 4.508 inches. If length is excessive, head bolt must be replaced.

Fig. 24 Cylinder head torquing sequence:

5. Torque head bolts to 22 ft.lbs. in order shown in Fig. 24.

Fig. 25 Cylinder head angle tightening:

6. Make paint marks on bolt heads as shown in Fig. 25.
7. Tighten each head bolt an additional 1/4 turn, Fig. 25, following torque sequence in Fig. 24. Then tighten each head bolt an additional 1/4 turn in sequence.
8. Apply motor oil to camshaft and journals.

Fig. 26 Applying sealer prior to installing caps:

9. Apply sealant as shown in Fig. 26.
10. Position camshaft in head with keyway facing up. Position camshaft caps on studs.
11. Apply engine oil to oil seal lip and insert seal. Repeat on other end of cylinder head.

Fig. 27 Tightening camshaft caps:

12. Torque camshaft nut to 15-20 ft.lbs. according to sequence in Fig. 27.
13. Install glow plugs and torque to 11-15 ft.lbs. Install cable.

Fig. 28 Installing injectors:

14. Install new corrugated washers so red paint mark is facing up, Fig. 28.
15. Install injection nozzles and torque to 43-51 ft.lbs.

INJECTION PUMP & BRACKET

1. Install injection pump bracket and torque bolts to 23-24 ft.lbs.
2. Align injection pump with mating mark and torque 2 nuts to 12-17 ft.lbs.
3. Install fuel injection pipes, and torque to 13-17 ft.lbs.
4. Tighten clip channels.

REAR TIMING MECHANISM

1. Install rear seal plate and torque bolts to 5-7 ft.lbs.
2. Install injection pump sprocket on pump shaft.
3. Turn injection pump sprocket until sprocket mark aligns with mark on seal plate.
4. Install injection pump sprocket and torque to 43-52 ft.lbs.
5. Install rear camshaft sprocket and torque to 41-48 ft.lbs.

Fig. 29 Aligning rear camshaft sprocket mark w/rear seal plate mark:

6. Align rear camshaft sprocket mark with rear seal plate mark, Fig. 29.
7. Install timing belt tensioner, spring and locknut. Turn tensioner fully clockwise and tighten locknut temporarily.
8. Install rear timing belt on injection pump sprocket, then rear camshaft sprocket.
9. Loosen locknut and allow tensioner spring to apply tension to timing belt.

FRONT TIMING MECHANISM

1. Install water pump, and torque mounting bolts to 23-34 ft.lbs.
2. Install brake vacuum pipe.
3. Install torque stop casing and torque to 23-34 ft.lbs.
4. Install seal plate and spacer and torque 6-8 ft.lbs.

Fig. 30 Aligning front camshaft sprocket:

5. Install front camshaft sprockets on camshaft, Fig. 30. Hold camshaft with 29mm wrench and torque bolt to 41-48 ft.lbs.

Fig. 31 Aligning front crankshaft sprocket:

6. Turn crankshaft back about 45 degrees to timing mark on oil pump housing, Fig. 31.
7. Install tensioner pulley and spring. Position tensioner over towards water pump and tighten locknut temporarily.
8. Install front timing belt.
9. Loosen tensioner lock bolt so tension is applied to timing belt.
10. Turn crankshaft clockwise twice to equalize tension on timing belt. Do not turn in reverse direction.
11. Torque front tensioner lock bolt to 23-34 ft.lbs.
12. Torque rear tensioner lock bolt to 14-20 ft.lbs.
13. Recheck timing marks on crankshaft and front camshaft sprocket, fuel injection pump sprocket and rear camshaft sprocket.
14. Timing belts should be tensioned so that front belt deflects .413-472 inch, and rear belt deflects .374 inch.
15. Install left, right, and rear timing covers. Torque mounting bolts to 5-7 ft.lbs.
16. Install No. 3 engine mount bracket and torque to 23-34 ft.lbs.
17. Install crankshaft pulley and torque bolts to 17-24 ft.lbs.

OIL COOLER ASSEMBLY

1. Apply coat of engine oil to center of oil cooler fitting on engine block.

Fig. 32 Installing O-rings in oil cooler:

2. Apply motor oil to 2 new O-rings and install in oil cooler assembly, Fig. 32.
3. Install oil cooler assembly and torque to 23-34 ft.lbs.
4. Install oil return pipe and torque to 17-26 ft.lbs.
5. Install oil filter.

INTAKE & EXHAUST MANIFOLD

1. Position intake manifold gasket.
2. Install intake manifold and torque to 12-17 ft.lbs.
3. Install oil cooler inlet pipe and torque to 6-8 ft.lbs. Torque inlet pipe bracket to 14-19 ft.lbs.
4. Install exhaust manifold and gasket, and torque to 16-20 ft.lbs.
5. Install 2 engine hangers.

NO. 3 ENGINE MOUNT

1. Install No. 3 engine mount and torque 16-24 ft.lbs.

CYLINDER HEAD COVER

Fig. 33 Applying sealant to valve cover:

1. Apply sealant to shaded area, Fig. 33.
2. Install cylinder head cover and torque to 5-7 ft.lbs.
3. Install PCV hose.

ALTERNATOR

1. Install alternator strap and bracket, and torque to 23-34 ft.lbs.
2. Install alternator and drive belt. Torque 8 mm bolt to 14-22 ft.lbs., front 10 mm bolt to 28-38 ft.lbs., and rear 10 mm bolt to 23-34 ft.lbs.
3. Install 2 alternator oil hoses.
4. Install oil pressure switch.
5. Install dipstick.