Service manual

TABLE OF CONTENTS FOR SECTION ‘D’

SECTION TITLE PAGE NO.

Page D-i

ENGINE REASSEMBLY

Engine Shop Rebuild and Parts Manual

CRANKCASE ASSEMBLY..............................................................................................................D - 1

Hone the Crankcase Cylinder Bore...................................................................................... D - 1

Reassemble the Pistons and Connecting Rods ................................................................... D - 1

Install the Piston Rings......................................................................................................... D - 2

Reassemble the Crankcase End Cover ............................................................................... D - 2

Install New Crankcase Bearing ............................................................................................ D - 2

Install New Crankshaft Bearing ............................................................................................ D - 3

Install New Crankshaft Seal ................................................................................................. D - 3

Install Crankshaft into Crankcase......................................................................................... D - 3

Install the Pistons in the Crankcase ..................................................................................... D - 3

Install the Balancer Shaft......................................................................................................D - 3

Set the Crankshaft and Balancer Shaft Endplay .................................................................. D - 3

Install Crankshaft Endplay Spacer and Balancer Endplay Spacer....................................... D - 4

Install Alignment Dowel Pins ................................................................................................ D - 4

Install New Oil Feed O-Ring................................................................................................. D - 4

Install Crankcase End Cover Gasket.................................................................................... D - 4

Install the Crankcase End Cover.......................................................................................... D - 4

Install the Oil Pump Gear Rotors.......................................................................................... D - 4

Install the Oil Pressure Switch.............................................................................................. D - 4

Install the Pulser Coil............................................................................................................ D - 4

Install the Fan Hub ............................................................................................................... D - 4

Set the Pulser Coil Air Gap................................................................................................... D - 5

Install the PVC Valve............................................................................................................ D - 5

Install the Oil Filter................................................................................................................ D - 5

LIST OF ILLUSTRATIONS

Fig. D-1 Crankcase Cylinder .......................................................................................................... D - 6

Fig. D-2 Piston and Connecting Rods ............................................................................................D - 7

Fig. D-3 Pistons and Connecting Rods con’t.................................................................................. D - 8

Fig. D-4 Crankcase End Cover, PCV Valve and Oil Filter.............................................................. D - 9

Fig. D-5 Crankshaft, Pistons and Balancer Shaft......................................................................... D - 10

Fig. D-6 Crankshaft, Pistons and Balancer Shaft con’t ................................................................ D - 11

Fig. D-7 Crankshaft and Balancer Shaft Endplay......................................................................... D - 12

Fig. D-8 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub.......................... D - 13

Fig. D-9 Oil Pump Gear Rotors, Oil Pressure Switch, Pulser Coil and Fan Hub con’t................. D - 14

Fig. D-10 Pulser Coil Air Gap....................................................................................................... D - 15