Assembly
Fig. 3 Assembling crankcase:
1. Thoroughly lubricate bearing inserts with clean engine oil.
2. Place main bearing inserts in position and install crankshaft. Thrust ring halves are positioned at rear main bearing saddle bore and may be installed before or after installing crankshaft.
3. Install main bearing caps and bearing inserts, ensuring caps are installed in proper location. Cap without notch goes at timing gear end of crankcase, then cap with one notch and so on.
4. Install new seal and gasket on flywheel end cover plate.
5. Install cover on crankcase, ensuring distance between cover seal and crankshaft is equal along entire circumference.
6. Secure flywheel to crankshaft with washer plate and six bolts, then block crankshaft with tool A 60369 or equivalent and torque flywheel bolts to 61 ft.lbs.
7. Thoroughly lubricate pistons and cylinder bores with clean engine oil and install piston and rod assemblies in cylinder bores with suitable piston ring compressors. Refer to ``Pistons & Connecting Rods.''
8. Thoroughly lubricate connecting rod bearing inserts and journals with clean engine oil.
9. Position connecting rod, with bearing inserts, on journals.
10. Install caps with bearing inserts and torque nuts to 38 ft.lbs.
11. Thoroughly lubricate auxiliary shaft bushings with clean engine oil.
12. Install shaft, then place gasket on lock plate and secure shaft in place with three bolts, lock washers, lock plate and new seal.
13. Install auxiliary shaft sprocket with bolt washer but do not tighten bolt fully.
14. Install new seal and gasket on timing gear end cover plate and install plate on crankshaft, ensuring indexing marks on cover plate are properly aligned.
15. Install oil pump and gasket, Fig. 3. Before final tightening of oil pump bolts, install oil pump and distributor drive gear, coupling it to gear on auxiliary shaft.
16. Temporarily install distributor.
17. Rotate auxiliary shaft, using sprocket, while tightening oil pump bolts alternately. If auxiliary shaft binds or crawls during rotation, loosen pump and repeat operation.
18. Install oil return pipe with one bolt and lock washer.
19. Install crankshaft sprocket and crankshaft pulley, then install pulley nut and, with flywheel blocked, torque pulley nut to 101 ft.lbs.
20. Install oil pan and gasket.
21. Install cylinder head assembly and new gasket complete with valves, springs, camshaft housing, manifolds and carburetor.
Fig. 4 Cylinder head bolt tightening sequence:
22. Gradually torque cylinder head bolts in proper sequence, Fig. 4, in two stages; torque to approximately 29 ft.lbs., torque to 69 ft.lbs.
23. Install timing belt shields.
24. Install camshaft sprocket with bolt and washer but do not fully tighten bolt at this time.
25. Install right engine mount with three bolts and lock washers.
26. Install spring tensioner in its seat in engine mount.
27. Install tensioner pulley support stud and bracket on crankcase.
28. Install tension pulley on bracket and secure temporarily with nut washers and spacer, but do not fully tighten at this time.
Fig. 5 Installing timing belt:
29. Using suitable tool, turn engine until mark (4), Fig. 5, on crankshaft sprocket is aligned with reference index (3).
30. Position camshaft sprocket so that marks (1 and 2) are aligned. Auxiliary shaft sprocket does not have to be aligned.
31. Move tensioner pulley toward engine mount and tighten nut to hold pulley in position, then install timing belt with slack on tensioner side. Always install a new timing belt. Timing belt tension must not be adjusted after initial installation.
32. Ensure timing belt teeth are perfectly coupled with sprockets.
33. Loosen nut holding tensioner pulley to allow tensioner to tighten belt, then torque tensioner pulley nut to 33 ft.lbs. and ensure timing marks are still aligned.
34. With flywheel blocked, torque auxiliary shaft sprocket bolt and camshaft sprocket bolt to 61 ft.lbs.
Fig. 6 Installing fuel pump:
35. Install fuel pump with gaskets, insulator, actuating rod, two nuts and washers in order shown, Fig. 6. Gasket comes in three different sizes which are used to adjust pump stroke.
36. Connect fuel line at carburetor.
37. Screw check valve into cylinder head and secure with locknut.
38. Install air pump and connect air hoses to air pump and check valve.
39. Install thermostat housing and gasket on crankcase.
40. Install water pump and gasket, torquing attaching bolts to 22 ft.lbs.
41. Install coolant pipe and gasket to water pump.
42. Connect coolant hoses to thermostat housing.
43. Install new air pump belt and check for approximately 1/2 inch deflection with moderate finger pressure.
44. Install EGR valve base, gasket, EGR valve and gasket.
45. Connect vacuum hose and EGR tube to EGR valve.
46. Connect EGR tube to carburetor base and exhaust manifold with spacer and gasket.
47. Install alternator mounting bracket, then the alternator.
48. Install new alternator drive belt, checking for approximately 1/2 inch deflection with moderate finger pressure, then install timing belt cover.
Fig. 5 Installing timing belt:
49. Turn crankshaft until timing marks are aligned, Fig. 5, then remove distributor cap and rotate shaft until rotor faces terminal corresponding to No. 4 cylinder.
50. Ensuring that rotor does not move, install distributor, securing with clamp.
51. Install crankcase breather and gasket on crankcase, torquing attaching bolt to 18.5 ft.lbs.
52. After ensuring clutch and flywheel surfaces are clean, align mating marks on clutch and flywheel.
53. With protruding portion of disc hub facing away from flywheel, loosely fasten clutch assembly to flywheel.
54. Using tool A 70210 or equivalent, center disc with pressure plate and gradually torque attaching bolts to 28 ft.lbs., then remove tool.
55. Lightly coat transmission shaft with suitable lubricant, then install transmission and covers on engine.
56. Install starter, then the oil dipstick and oil filter.