Engine Assembly

Fig. 9 Valve oil seal installation. 1982-86:

1. Install valve oil seal, Fig. 9.

Valve spring installation:

2. Apply clean engine oil to valve stem and lip of valve seal, then install valve and valve components. Install valve spring with narrow pitch side toward cylinder head side, Fig. 10.
3. Apply clean engine oil to camshaft and bearing interior, then install camshaft.
4. Assemble, then install rocker shaft assembly. Note the following:
a. Apply clean engine oil to camshaft and bearing interior.
b. Install rocker shaft so that oil hole in shaft faces downward.
c. Ensure that cutout in center retainer of rocker shaft faces exhaust manifold.
d. Install new bolt stoppers on Nos. 1 and 5 rocker shaft attaching bolts.
5. Install cylinder head cover, then the camshaft sprocket.

ENGINE ASSEMBLY

Main bearing identification:

1. Install upper main bearings in proper position in cylinder block, Fig 13. Apply clean engine oil to main bearing surfaces on both sides of cylinder block and cap.

Main bearing cap bolt tightening sequence:

2. Install crankshaft, then the lower main bearings and caps. Torque bolts to specifications in sequence shown, Fig. 14.
3. Measure crankshaft endplay and make sure it is within specifications.
4. Apply clean engine oil to the rear oil seal and mating shaft, then install the oil seal into retainer and install assembly to cylinder block. The lip of the oil seal must face to the outside of the crankshaft.

Fig. 15 Piston & connecting rod assembly:

Fig. 16 Piston ring installation:

5. Install piston and rod assemblies into corresponding cylinders. Assemble so that front mark on piston head, Fig. 15, faces front of engine. Set piston rings as shown in Fig. 16.
6. Install connecting rod caps and torque cap nuts to specifications. Make sure that cylinder numbers face in same direction.
7. Install rear plate, then the flywheel or drive plate. Torque retaining bolts to specifications.
8. Carefully install jack shaft, then the jack shaft locating plate.
9. Install water pump with a new gasket.
10. Install oil slinger, then the cylinder block cover with oil seal collar.
11. Install jack shaft pulley. Torque pulley retaining bolt to 6.5-8.7 ft. lbs.
12. Install crankshaft sprocket, then temporarily install the tensioner pulley.
13. Install cylinder head assembly as follows:
a. Clean cylinder block and head mating surface. Do not apply sealant to mating surface.
b. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke. This will align mark on crankshaft sprocket with mark on cylinder block cover.

Camshaft sprocket timing mark alignment:

c. Align mark on camshaft sprocket with mark on cylinder head cover, Fig. 12.

Fig. 17 Cylinder head bolt tightening sequence:

d. Install cylinder head assembly with new gasket. Torque bolts in sequence, Fig. 17, to 22 ft. lbs.
e. Retorque all cylinder head bolts in sequence to 51 ft. lbs., then loosen all bolts completely.
f. Torque bolts to 22 ft. lbs., then to 51-54 ft. lbs. in sequence.
14. Install spark plugs and torque to specifications.
15. Install timing belt as follows:
a. Ensure that timing marks are aligned, then rotate tensioner clockwise approximately 70 to 80° and temporarily tighten locknut.
b. Position timing belt on sprocket, then loosen tensioner locknut so that tensioner pushes on belt.
c. Rotate camshaft sprocket clockwise approximately 20°, then torque tensioner locknut to 12-15 ft. lbs. while preventing tensioner from turning.
16. Install water pump pulley, then the upper and lower timing belt covers with spacer.
17. Install crankshaft pulley and torque retaining bolt to specifications.
18. Install exhaust manifold and torque nuts to specifications.
19. If equipped, install A/C compressor and/or power steering pump brackets.
20. Install oil pump with new gasket. Torque attaching bolts and nuts to 6.5-10.1 ft. lbs. on 1982-84 models or 5.8-7.2 ft. lbs. on 1985-86 models.
21. Install fuel pump with insulator. Torque attaching nuts to 6.7-8.7 ft. lbs.
22. Install oil filter, then the alternator bracket and alternator.
23. Install intake manifold with carburetor. Torque nuts to specifications.
24. Install thermostat housing with distributor. Torque thermostat housing attaching bolt to 2.9-4.3 ft. lbs.
25. Install clutch assembly using tool No. KV30101000. Torque retaining bolt to 5.1-7.2 ft. lbs. on 1982-84 models, or 16-22 ft. lbs. on 1985-86 models.