Engine Assembly

1. Set main bearings at the proper porting of cylinder block.
2. Install baffle plate and cylinder block net.
3. Apply engine oil to main bearing surfaces on both sides of cylinder block and cap and then install crankshaft.

Fig. 16 Main bearing cap & cylinder head bolt tightening sequence:

4. Install main bearing cap and torque bolts to specifications, in sequence, Fig. 16.
5. Make sure that crankshaft has proper endplay.

Fig. 17 Side oil seal installation:

6. Install side oil seals into rear main bearing cap, Fig. 17. Prior to installing, apply sealant to seals.

Fig. 18 Rear oil seal installation:

7. Install rear oil seal, Fig. 18.
8. Install rear end plate.
9. Install flywheel securely, and tighten bolts to specified torque.

Fig. 14 Piston & rod assembly:

10. Insert pistons in corresponding cylinder. Install so that notch mark on piston head faces to front of engine, Fig. 14.
11. Install and torque connecting rod caps.
12. Rotate crankshaft until No. 1 piston is at top dead center.
13. Make sure that both valves on No. 1 cylinder are closed, and that camshaft sprocket is correctly indexed. Install cylinder head. Do not rotate crankshaft and camshaft independently after cylinder head installation, or valves will contact pistons.
14. Install crankshaft sprocket, oil pump drive gear, and oil thrower.

Fig. 19 Timing chain installation (Typical):

15. Install timing chain by aligning mating marks on timing chain with the correct index mark on the camshaft sprocket and the mark on crankshaft sprocket, Fig. 19.

Fig. 20 Timing chain tensioner installation:

16. Install chain guide and chain tensioner and adjust so that tensioner spindle is flush with guide, Fig. 20.
17. After tensioner has been installed, check the amount of timing chain stretch. If timing chain is stretched excessively:
a. Remove tensioner, timing chain, and camshaft sprocket.
b. Advance camshaft sprocket to next dowel position and complete installation of camshaft sprocket.
c. If camshaft dowel pin is already in No. 3 position of camshaft sprocket, replace timing chain and tensioner.

Fig. 21 Front cover installation:

18. Press new oil seal into front cover and install front cover with new gasket, Fig. 21.
19. Install crankshaft pulley and water pump. Make sure No. 1 cylinder is at T.D.C. on the compression stroke.

Fig. 16 Main bearing cap & cylinder head bolt tightening sequence:

20. Torque cylinder head bolts in three stages in sequence, Fig. 16, to final specification.

Fig. 22 Oil pump installation:

21. Install oil pump and drive spindle in front cover, Fig. 22.
22. Install fan pulley, fan coupling and fan.
23. Install idler pulley and bracket for power steering if equipped.
24. Install engine right side parts:
a. Spark plugs.
b. Oil pressure switch.
c. Oil level gauge.
d. Install engine mounts on both sides.
25. Install intake and exhaust manifolds by reversing removal procedure.
26. Install thermostat assembly.
27. Install oil strainer and oil pan with new gasket.
28. With No. 1 piston at T.D.C. of compression stroke, install distributor as outlined under ``Distributor, Replace.''
29. Install distributor cap and connect high tension cables.
30. Install air conditioning brackets where equipped.
31. Install alternator and power steering brackets, alternator, and fan belts.
32. Install auxiliary cooling fan and duct.
33. Install clutch on manual transmission models.
34. Install transmission in the reverse of removal, install starter, and install assembly in vehicle in the reverse of the removal procedure.
35. After installation, fill engine oil and coolant to specified levels and make all necessary adjustments.