Engine Assembly

During assembly procedures, apply a suitable lubricant to mating surfaces of components.

1. Install lower spring cups, then valve stem seals. Assemble springs, washers, keepers and valves in reverse order of removal.
2. Insert camshaft into cylinder head. Ensure lubricating holes on rockers and rocker arm shafts align.
3. Install rocker shafts, rocker arms, springs and spacers in cylinder head.
4. Install rocker arm shaft and camshaft retaining plate.
5. Install cylinder head rear inspection plate and gasket.
6. Install circlips on rocker arm shafts.
7. Place a drop of non-hardening cement into grooves of rear main seal carrier and cylinder block.
8. Insert rope seals into their grooves, using tool No. J35222 or equivalent. Do not alter or modify length or shape of rope seal.
9. Select main bearing inserts from three types available as follows:
a. Type A, used on block side of Nos. 1, 3 and 5 main bearings is smooth and incorporates an oil hole.
b. Type B, used on the cap side of main bearings 1, 3 and 5, is smooth but does not incorporate an oil hole.
c. Type C, is used on main bearings 2 and 4 on cap and block side and incorporates a groove an oil hole.
10. Install half thrust washers on either side of center main, with grooves facing crankshaft.
11. Install crankshaft.
12. Install main bearing caps, then torque to specifications.
13. Check endplay with tool No. J35331 or equivalent. Endplay should measure .004-.011 inch (.090-.270 mm). Adjust endplay to specifications by inserting thrust washers of different thicknesses.

Fig. 7 Rope seal carrier:

14. Apply a suitable silicone compound to lateral grooves (1) and contact faces of rope seal carrier (2), Fig. 7.
15. Install rope seal carrier.

Fig. 8 Tubular seal installation:

16. Insert a tubular seal into each groove (1), Fig. 8, using tool No. J35326 or equivalent.
17. Install flywheel and flywheel plate. Apply a suitable locking compound to threads of bolts, then torque to specifications. Retain flywheel, using tool No. J35317 or equivalent, then ensure crankshaft rotates freely when tool is removed.

Fig. 9 Piston installation:

18. Install piston and rod assemblies using suitable compressor. Reference on rod (a) must point toward oil filter side of engine, Fig. 9. Machined face of nuts (A) must ride against rod caps. Torque nuts to specifications.
19. Position crankshaft with pistons 1 and 4 at TDC and lock in this position using flywheel locking pawl.

Fig. 10 Positioning camshaft:

20. Position camshaft over valves of No. 1 cylinder in such a way that both valves are closed. Align threaded hole (4) of camshaft sprocket, Fig. 10, and smooth hole (5) with exhaust rocker shaft center line.

Fig. 11 Centering dowel installation:

21. Install two centering dowels (1), Fig. 11. Place dry head gasket on engine block with marking DESSUS-TOP facing up.

Fig. 12 Cylinder head torquing sequence:

22. Install cylinder head, then apply a suitable lubricant to head bolts. Insert attaching bolts and washers, then torque to specifications in sequence shown in Fig. 12, first torque to 37 ft. lbs. (84 Nm), then to 61 ft. lbs. (84 Nm).
23. Position Woodruff key in crankshaft, then install pinion with double row of teeth toward block.

Fig. 13 Timing chain installation:

24. Place camshaft pinion, with insert facing camshaft flange, on camshaft. Position punch mark ``b'' on pinion, Fig. 13, in line with reference on cylinder head. Remove pinion and reinstall with timing chain in place.
25. Install chain guide pads. Use adjustable pad to remove slack in timing chain.
26. Recheck alignment of references ``b'' and ``c'', Fig. 13.
27. Install timing chain tensioner as follows:
a. On Brampton tensioner release pad by turning a 3 mm Allen wrench counterclockwise. Install lock plate and bolt, then bend lock plate.
b. On Winklofer tensioner, insert support plate under tensioner, then insert and tighten attaching bolt. Unload tensioner, using a suitable screwdriver, by turning it counterclockwise.
28. Install oil pump centering dowels. Position oil pump with chain installed, then torque bolts to 14 ft. lbs. (20 Nm).
29. Apply a suitable lubricant to new seal, then install in timing chain housing cover.
30. Place spacer and key on end of crankshaft, then place timing chain centering dowels into block.
31. Apply a suitable grease to gaskets, then a thin coat of silicone sealant to top face of timing chain cover. Install timing chain cover.
32. Install water pump, power steering pump and alternator bracket.
33. Apply a suitable silicone sealing compound to top surface of protruding head gasket.

Fig. 14 Upper timing chain cover installation:

34. Apply a suitable grease to timing chain cover upper half gasket, then ensure timing chain cover upper half centering dowels are in place. Install timing chain upper half and new gasket. Tighten bolts in numerical order, Fig. 14, beginning with No. 12. Remember to install fan brush wire support (11).

Fig. 15 Distributor drive shaft installation:

35. Install distributor driveshaft with No. 4 cylinder in TDC position of compression stroke. Insert shaft with thin side ``a,'' Fig. 15, of drive gear toward cylinder head. When seated, slot should be positioned as shown. Remove flywheel locking pawl.

Fig. 16 Valve positions:

Fig. 17 Valve adjusting sequence:

36. Adjust valves, Fig. 16, as shown in Fig. 17.
37. Install valve cover, then the ignition wire supports.

Fig. 18 Oil pan reinforcing plates:

38. Install oil pan, positioning reinforcing plates as shown, Fig. 18.
39. Lock flywheel, then install clutch plate and pressure plate, using suitable centering tool. Torque bolts to 18 ft. lbs. (24 Nm).
40. Install oil level sender, then torque to 14 ft. lbs. (20 Nm).
41. Install crankshaft pulley, then torque to 97 ft. lbs. (132 Nm).
42. Remove flywheel locking pawl.
43. Install front lifting bracket.
44. Install intake manifold, power steering pump, motor mounts, coolant inlet housing, oil filter and dipstick.
45. Install starter, distributor, spark plug wiring harness, alternator and accessory drive belts.
46. Install turbocharger, then the turbocharger ducting pipes.
47. Install A/C compressor mount.