Engine Assembly
Fig. 2 Valve & valve components:
Cylinder Head Assembly
1. Install valves and valve components in order shown, Fig. 2. Apply clean engine oil to valve stem and lip of valve oil seal. Install valve spring with narrow pitch (painted) side toward cylinder head side.
2. Install camshaft so that the dowel pin at front end is at 12 o'clock position on vehicles less camshaft locate plate.
Fig. 3 Rocker shaft assembly:
3. Assemble, then install rocker shaft assembly, Fig. 3. Note the following:
a. Intake rocker shaft is identified by a slit on front surface.
b. Assemble both shafts so that punched marks on front surface are on top.
c. Torque bolts to specifications. Tighten bolts in two or three steps, beginning with center bolts and working outward.
4. Rotate camshaft until No. 1 piston is at TDC of compression stroke.
5. Install fuel pump cam. Torque retaining bolt to 58-65 ft. lbs.
6. Install cylinder head rear cover. Torque attaching bolts to 4.3-7.2 ft. lbs.
Piston & Rod Assembly
1. Assemble pistons, piston pins and connecting rods of designated cylinders. Note the following:
a. Apply clean engine oil to piston and small end of connecting rod before pressing pin into rod.
b. Assemble so that oil hole in connecting rod big end points toward right side of cylinder block
2. Install piston rings. Ensure that identification marks on rings face upward.
Engine Assembly
1. Install baffle plate into crankcase.
2. Install upper main bearings into cylinder block. Note that the No. 3 bearing is the only one of the flanged type. Upper and lower bearings are not interchangeable. Upper bearings can be identified as those having an oil groove.
3. Apply clean engine oil to main bearing surfaces on both sides of cylinder block and cap.
Fig. 4 Main bearing cap bolt tightening sequence. 1984:
4. Install crankshaft, then the lower main bearings and caps. Torque bolts to specifications in two or three steps in sequence shown, Fig. 4. Ensure that crankshaft turns smoothly.
5. Measure crankshaft endplay and make sure it is within specifications.
6. Apply clean engine oil to lip of rear oil seal and mating shaft and coat inner surface of seal with grease. Install seal in retainer, then install the retainer to cylinder block.
7. Install rear end plate and flywheel. Torque retaining bolts to specifications.
Fig. 6 Piston & connecting rod assembly:
Fig. 7 Piston ring installation:
8. Install lubricated piston and rod assemblies into corresponding cylinders. Assemble so that front mark on piston head, Fig. 6, faces front of engine. Set piston rings as shown in Fig. 7.
9. Install connecting rod bearing caps and torque cap nuts to specifications. Ensure that cylinder numbers face in same direction.
10. Install cylinder head as follows:
a. Thoroughly clean cylinder block and head mating surface. Do not apply sealant to mating surface.
b. Install camshaft sprocket and torque retaining bolt to specifications.
c. Ensure there is sufficient clearance between valves and pistons. Loosen rocker arm adjusting screws to draw valves in, if necessary.
Fig. 8 Cylinder head bolt tightening sequence:
d. Install cylinder head assembly with new gasket. Torque bolts in sequence, Fig. 8, to 22 ft. lbs.
e. Retorque all bolts in sequence to 58 ft. lbs., then completely loosen all bolts.
f. Torque bolts to 22 ft. lbs., then to 54-61 ft. lbs. in sequence. If an angle wrench is available, instead of torquing bolts to 54-61 ft. lbs., turn bolt No. 8 83-88°, and other bolts to 75-80°, in clockwise direction.
11. Install oil pump and torque attaching bolts to 9-12 ft. lbs.
12. Install water pump and torque attaching bolts to 9-12 ft. lbs.
13. Install timing belt tensioner. Do not tighten bolts at this time.
14. Install timing belt plate and crankshaft sprocket. Ensure timing marks on sprocket face forward.
Fig. 9 Timing belt installation:
15. Install timing belt on camshaft and crankshaft sprockets with timing marks aligned, Fig. 9.
Fig. 10 Timing belt tensioner adjustment:
16. Torque belt tensioner attaching bolts to 13-16 ft. lbs. Set belt tensioner spring by first hooking one end on bolt ``B'' side, Fig. 10, then hooking opposite end on tensioner bracket pawl. Tighten bolt ``B,'' then bolt ``A'' and belt tension will automatically be set to specifications.
17. Install front cover oil seal.
18. Install lower front cover with new gaskets. Torque attaching bolts to 2.2-3.6 ft. lbs.
19. Install vibration damper with backing plate. Torque retaining bolt to specifications.
20. Install crankshaft pulley and torque retaining bolts to 9-10 ft. lbs.
21. Temporarily adjust valve clearance as follows:
a. Rotate crankshaft until high point of No. 1 cam lobe is at the 6 o'clock position.
Fig. 11 Valve clearance adjustment:
b. Adjust valves 1, 4, 6 and 7, Fig. 11.
c. Insert feeler gauge between tip of valve stem and rocker arm screw and adjust valve clearance to the following specifications: exhaust valves, .009 inch; intake valves, .008 inch.
d. Rotate crankshaft until high point of No. 1 cam lobe is at the 12 o'clock position, then adjust remaining valves.
22. Install valve rocker cover with new gasket. Torque attaching bolts to .7-2.2 ft. lbs. in a crisscross pattern.
23. Install upper front cover with new gasket and torque attaching bolts to 2.2-3.6 ft. lbs.
24. Install oil strainer and oil pan with new gasket. Apply suitable sealant to oil pan mating surface and torque attaching bolts to specifications in a crisscross pattern.
Fig. 12 Distributor installation:
25. Install engine outer parts in reverse order of removal. Refer to steps 1 through 13 under ``Engine Disassembly.'' Install distributor as positioned in Fig. 12.