Service manual
ENGINE
ASSEMBLY
Reassembly
Precautions
• Be careful not to mix bolts and nuts. Metric and S.A.E.
bolts are used on various engine assemblies.
• During assembly, recheck clearances and insure that parts
are being assembled in their proper order and facing in the
correct direction in relation to the engine block, such as,
pistons, piston rings, bearings and bearing caps.
• Apply lubricating oil to moving parts during assembly.
Insure that moving parts, when assembled on the engine,
rotate or slide and are not subject to binding
or
excessive tension.
•
If
there are mating marks scribed during disassembly,
reference them correctly for assembly.
• Use new gaskets, lockwashers, O-rings, etc.
• Tighten the holts and nuts on important parts
of
engine to
specified torques using a reliable torque wrench.
• Use liquid sealants when required on nuts, bolts and
gaskets. Refrain from using tape sealants.
NOTE:
Also refer
to
Sealants and Lubricants
in
this
manual.
Be aware
of
these common problems that can occur during
assembly.
Insufficient Lubrication. Heavily oil sliding and
reciprocating parts, lightly oil head bolts and other fasteners,
except those that penetrate into the water jacket. These
fasteners should be sealed with Permatex
No.2
or the
high-tack equivalent.
Reversed orientation. Most gaskets, many bolt washers, and
all thermostats are asymmetrical.
Mechanical damage. Run fasteners down in approved
torque sequences and in three
steps-II2,
213,
and
111
torque.
Exceptions are torque-to-yield bolts and rocker arm shaft
fasteners. The former are torqued as indicated. The
latter-rocker shaft fasteners-should be brought down in very
small increments, working from the center bolts out. Gaskets,
especially head gaskets, might be damaged during assembly,
they should
be
positioned with great care.
AT
9(J'
INTERVALS
TOP
RING
&
OIL
EXPANDER
SPRING
FRONT
...
__
.......
-
\
TOP
RING
•
~SECOND
-
~RING
_-50
.............
ENGINE
ASSEMBLY
1.
Install the valves
in
cylinder head. Using the valve
spring lifter arm and pivot, assemble the valve, lower
spring seat, oil deflector, inner valve spring, outer valve
spring, upper spring seat and taper sleeve in this order.
NOTE:
The
oil deflector should
be
installed
on
the
intake
valve
only.
2.
Assemble the rocker
arm
shaft, rocker shaft brackets
and
rocker arms. Note that the front end
of
the rocker
shatt is identified by a pin protruding from the top and a
larger oil hole between the supply holes serving #1 and
#2 rocker arms. This pin fits a slot in the
#1
rocker shaft
support which prevents the shaft from turning and cutting
off the lube oil to the rocker arms and valves. Use the fol-
lowing order
of
assembly:
a.
Spring
d.
Rocker
b. Rocker e. Wave washer
c. Rocker shaft support
f.
snap ring
,JAM
NUT
TAPER
PI~
®.
•
~BUSHING
~
~
®
~
() '-....
......
./SPRING
#1
ROCKER
_-"'II"IIlIJO
~
WAVE
WASHER
i\~
SNAP
--RING
TAPER
PIN
RECESS
OC~SHAfT/(@4sf5
SUPPORT
TAPER
PIN
HOLE
3. Assemble the connecting rod, piston
and
piston rings.
Arrange the piston and the connecting rod as shown and,
using the piston pin installer, insert the piston pin through
the piston and connecting rod until the piston pin (wrist
pin) snap rings can be fitted. Fit the piston pin snap rings
to their respective grooves. Install the piston rings to ring
grooves on the piston with the inscription mark on ring
upward using a suitable piston ring expander.
I
FRONT
OF
PISTON
IS
INDICATED
BY
A
BOSS
ON
THE
BOTTOM
NEAR
THE
OIL
HOLE
CHECK
THE
PISTON
RING
GAPS
WITH
CARE.
NEW
RINGS
ARE
PACKAGED
WITH
DETAILED
INSTRUCTIONS
THAT
OFTEN
SUPERSEDE
THE
SERVICE
MANUAL.
24