Engine Assembly

Valve spring installation:

1. Install valve component parts, noting the following:
a. Always use new valve oil seal.
b. Before installing valve oil seal, install valve spring seat.
c. Install valve spring with narrow pitch side toward cylinder head side, Fig. 10.
2. Install camshaft and upper front cover in cylinder head with new camshaft oil seal.

Fig. 11 Aligning camshaft knock pin:

3. Set knock pin upper side, Fig. 11.

Camshaft sprocket timing mark alignment:

4. Install camshaft sprocket, aligning camshaft sprocket mark with upper front cover mark, Fig. 12.
5. Align crankshaft sprocket mark with lower front cover mark.
6. Install intake manifold, torquing attaching bolts to 12-15 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 pin and small end of connecting rod before pressing pin into rod.
b. Assemble piston to rod so that oil hole on connecting rod points toward right side of cylinder block.
2. Install piston rings. Ensure that identification marks on rings face upward.

ENGINE ASSEMBLY

Fig. 15 Piston & connecting rod assembly:

1. Assemble pistons, noting the following:
a. Numbers are stamped on connecting rod and cap corresponding to each cylinder, Fig. 15.
b. Arrange so that front mark on piston head faces toward front of engine.
c. When pressing piston pin in connecting rod, apply engine oil to pin and small end of connecting rod.
d. After assembling, ensure piston swings smoothly.

Fig. 16 Piston ring installation:

e. Set piston rings as shown, Fig. 16. Install so that stamped mark on ring faces upward and apply engine oil to sliding parts.

Main bearing identification:

2. Set main bearings in proper position on cylinder block, noting the following:
a. Only center bearing (No. 3 bearing) is flanged, Fig. 13.
b. Nos. 2 and 4 bearings and Nos, 1 and 5 bearings are the same.
c. Upper and lower bearings are not interchangeable as upper bearings have oil grooves.
3. Apply engine oil to main bearing surfaces on both sides of cylinder block and cap.

Main bearing cap bolt tightening sequence:

4. Install crankshaft and main bearing caps, torquing bolts, in sequence, Fig. 14, to 36-43 ft. lbs., noting the following:
a. Torque bolts in two or three stages.
b. Ensure crankshaft turns smoothly by hand.
5. Ensure crankshaft endplay, measured at center bearing, is .002-.007 inch.
6. Using suitable tool, install pistons in respective cylinders, noting the following:
a. Be careful not to scratch cylinder wall with connecting rod.
b. Apply engine oil to cylinder wall, piston and bearing.
c. Arrange so that front mark on piston head faces toward front of engine.
7. Install connecting rod bearing caps, torquing nuts to 23-27 ft. lbs.
8. Measure connecting rod side clearance. If clearance is not .0039-.0146 inch, replace connecting rod and/or crankshaft as necessary.
9. Install cylinder head. Refer to ``Cylinder Head, Replace.''
10. Install oil pan. Refer to ``Oil Pan, Replace.''
11. Install water pump. Refer to ``Water Pump, Replace.''
12. Install timing belt. Refer to ``Timing Belt, Replace.''

Fig. 5 Engine outer components. 1987-88:

13. Install external components on engine, Fig. 5.