Service manual
ENGINE
REASSEMBLY
Take the following precautions:
• Be careful
no.t
to.
mix
bo.lts
and
nuts.
Metric and S.A.E.
bo.lts
are used
o.n
vario.us
engine assemblies.
• During assembly, recheck clearances and insure that parts
are
being assembled
in
their
pro.per
o.rder
and facing in the
co.rrect
directio.n
in
relatio.n
to.
the engine
blo.ck,
such
as,
pisto.ns,
pisto.n
rings, bearings and bearing caps.
• Apply lubricating
o.il
to.
mo.ving
parts during assembly.
Insure that
mo.ving
parts, when assembled
o.n
the engine,
ro.tate
o.r
slide and are
no.t
subject
to.
binding
o.r
excessive
tensio.n.
•
If
there are mating marks scribed during disassembly,
reference them
co.rrectly
fo.r
assembly.
•
Use
new
gaskets, lockwashers,
o.-rings,
etc.
• Tighten
the
bo.lts
and nuts
o.n
impo.rtant
parts
o.f
engine
to.
specified
to.rques
using a reliable
to.rque
wrench.
• Use liquid sealants when required
o.n
nuts,
bo.lts
and
gaskets. Refrain
fro.m
using tape sealants.
Be
aware
of
these common problems that can
occur during assembly.
Insufficient Lubrication. Heavily
o.il
sliding and
reciprocating parts, lightly
o.il
head
bo.lts
and
o.ther
fasteners,
except
tho.se
that penetrate
into.
the water jacket. These
fasteners
sho.uld
be sealed with Permatex
No..
2
o.r
the
high-tack equivalent.
Reversed orientation.
Mo.st
gaskets, many
bo.lt
washers,
and all
thermo.stats
are asymmetrical.
Mechanical damage. Run fasteners
do.wn
in
appro.ved
to.rque
sequences and in three steps-ll2, 2/3, and III
to.rque.
Exceptio.ns
are
to.rque-to.-yield
bo.lts
and
ro.cker
arm shaft
fasteners. The
fo.rmer
are
to.rqued
as
indicated. The
latter-rocker shaft fasteners-sho.uld
be
bro.ught
do.wn
in
very
small increments,
wo.rking
fro.m
the center
bo.lts
o.ut.
Gaskets,
especially head gaskets, might
alSo.
be
damaged during·
assembly, they
sho.uld
be
po.sitio.ned
with great care.
FRONT
___
........
-
FRONT
OF
PISTON
IS
INDICATED
BY
. A BOSS ON THE
BOTTOM NEAR THE
OIL HOLE
ENGINE
ASSEMBLY
1.
Install the valves
in
cylinder head. Using
the
valve
spring lifter arm and pivo.t, assemble the valve,
lo.wer
spring
seat,
o.il
deflecto.r,
inner valve spring,
o.uter
valve
spring,
upper spring seat
and
taper sleeve in this
o.rder.
NOTE:
The oil deflector should be installed on the intake
valve only.
2.
Assemble the
rocker
arm shaft, rocker shaft
brackets and
rocker
arms.
No.te
that the
fro.nt
end
o.f
the
rocker shaft is identified by a pin protruding
fro.m
the
to.p
and
a larger
o.il
ho.le
between the supply
ho.les
serving
#1
and #2
rocker
arms.
This pin fits a
slo.t
in the
#1
ro.cker
shaft
suppo.rt
which prevents the shaft
fro.m
turning and cutting
o.ff
the lube
o.il
to.
the rocker arms and valves.
dJJ
ROCKER
ARM
~
.EV
ASSEMBLY
TJ.
••
~
\
I'
~.
/.
TA.PERPINHQLE
.J
112
ROCKER
.'
-ll-:;;",,,.:i1
'.
'ROCKER SHAFT/ .
()'
,\
SUPPORT
SCALLOP
3.
Assemble the connecting rod, piston and piston
rings.
Arrange the pisto.n and the
co.nnecting
rod as
sho.wn
and,
using the
pisto.n
pin installer, insert the
pisto.n
pin
thro.ugh
the
pisto.n
and
co.nnecting rod until the
pisto.n
pin
circlips can
be
fitted. Fit the
pisto.n
pin
circ1ips
to.
their
respective
gro.o.ves.
Install the
pisto.n
rings
to.
ring
groo.ves
o.n
the
pisto.n
with the inscriptio.n mark
o.n
ring upward.
______
PISTON
RINGS/
_1ST
_2ND
mRD'OILRING
:
CHECK
THE PISTON RING
GAPS
WITH CARE.
NEW
RINGS
ARE
PACKAGED
WITH DETAILED
INSTRUCTIONS
. THAT OFTEN SUPERSEDE
THE SERVICE MANUAL.
MARK
Engines & Generators
23