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8-42
deposits from the upper end of the
cylinder bores. Remove the cylinder
ridges with a ridge cutter. Follow
the instructions furnished by the tool
manufacturer. Never cut into the
ring travel area in excess of
1/
32
inch when removing ridges.
15. Make sure all bearing caps
(main and connecting rod) are
marked so they can be installed
in their original locations. Turn
the crankshaft until the connecting
rod being removed is down. Remove
the connecting rod
cap.
16. Push the connecting rod and
piston assembly out the top of the
cylinder with the handle end of a
hammer. Avoid damage to the
crankpinorthecylinderwall when
removing the piston and rod.
17. Remove the bearing inserts
from the connecting rods and caps.
Remove the main bearing
caps.
18. Carefully lift the crankshaft out
of the cylinder block so that the thrust
bearing surfaces are not damaged.
Handle the crankshaft with care
to avoid possible fracture or
damage to the finished surfaces.
19. Remove the rear journal oil
seal from the block and rear main
bearing cap. Remove the main bear-
ing inserts from the block and
bearing caps.
20. Remove the camshaft thrust
plate. Carefully remove the camshaft
by pulling it toward the front of the
engine. Use caution to avoia dam-
aging the journals and lobes.
21. Remove the camshaft rear
bearing bore plug (Fig. 28).
22. Remove the camshaft bearings
(Fig. 48).
23. Remove the dipstick tube and
the plug or drain.
ENGINE ASSEMBLY
1. Install the camshaft bearings
and rear bore plug by following
steps 3 and 4 under Camshaft Bear-
ing Replacement.
2. The camshaft and related parts
are shown in Fig. 25. Oil the cam-
shaft journals and apply Lubriplate
to all camshaft lobes. Carefully slide
the camshaft through the bearings.
3. Install the thrust plate. Torque
the retaining screws to specifications.
4. The crankshaft and related
parts are shown in Fig. 44. Be sure
that the rear journal oil seal grooves
are
clean. Install a new rear journal
oil
seal in the Block (Fig. 45) and
rear main bearing cap
(Fig.
32).
GROUP
8-
ENGINE
After installation, cut the ends of
the seals flush.
5. If the crankshaft main bearing
journals have been refinished to a
definite undersize, install the correct
undersize bearings. Be sure the bear-
ing bores are clean. Place the upper
main bearing inserts m position in
the bore with the tang fitting in the
slot provided.
6. Install the lower main bearing
inserts in the bearing caps.
7. Carefully lower the crankshaft
into place. Be careful not to dam-
age the bearing surfaces.
8. Check the clearance of each
main bearing following steps 10
through 13 under Main Bearing Re-
placement. In step 10, place the
Plastigage on the crankshaft jour-
nal instead of in the bearing cap.
(Fig. 46).
9. After the bearings have been
fitted, apply a light coat of engine
oil to the journals and bearings.
Install all the bearing caps, except the
thrust bearing cap No. 5 bearing. Be
sure that the main bearing caps
are installed in their original
locations. Torque the bearing cap
bolts to specifications.
10. Install the thrust bearing cap
by following steps 12 through 15
under Crankshaft Installation.
11. Check the crankshaft end play
by following steps 17 through 19
under "Crankshaft Installation."
12. Turn the engine on the work
stand so that the front end is up.
13. Oil the piston rings, pistons,
and cylinder walls with light engine
oil.
14.
Be
sure to install the pistons
in the same cylinders from which
they were removed, or to which they
were fitted. The connecting rod and
bearing cap are numbered from 1 to
6
beginning at the front of the
engine. The numbers on the con-
necting rod and bearing cap must
be on the same side when installed
In the cylinder bore.
If
a conqecting
rod is ever transposed from one
block or cylinder to another, new
bearings should
be
fitted and the
connecting rod should be numbered
to correspond with the new cyUnder
number.
15. Make sure the ring gaps are
properly spaced around the circum-
ference of the piston.
16. Install a piston ring compres-
sor on the piston and push the piston
in with a hammer handle until it is
slightly below the top of the cylinder
(Fig.
33
~
Be sure to guide the con-
necting rods to avoid damaging the
crankshaft journals. Install the pis-
ton with the notch in the piston head
toward the front of the engine.
17. Check the clearance of each
bearing following the procedure
un-
der Connecting RC>d Bearing
Re-
placement.
18. After the bearings have been
fitted, apply a light coat of engine
oil to the journals and bearings.
19. Turn the crankshaft throw
to
the bottom of its stroke. Push the
piston all the way down until the
connecting rod bearing seats on the
crankshaft journal.
20. Install the connecting rod cap.
Torque the nuts to specifications.
21. After the piston and
connect·
ing rod assemblies have been
install-
ed, check the connecting rod
side
clearance on each crankshaft journal
(Fig. 34)
22. Lubricate the timing chain
and sprockets with engine oil. Place
the keys in position in the slots on
the crankshaft and camshaft.
23. Oil the timing chain. Position
the sprockets and timing chain on
the camshaft and crankshaft. Be
sure the timing marks on the
sprockets and chain are positioned as
shown in Fig. 21.
24. Install the camshaft sprocket
retaining bolt and washer. Torque
the bolt to specifications.
25. Clean the cylinder front cover
and the gasket surface of the cylinder
block.
26. Install a new crankshaft front
oil seal.
27. Coat the gasket surface of the
block and the cover with oil-resistant
sealer. Position a new gasket on the
block.
28. Using tool 6019-A, install the
cylinder front cover on the
block.
Torque the screws to
specifications.
Apply Lubriplate to the seal
surface,
and to the seal running surface of the
damper.
29. Line up the crankshaft
damper
keyway with the key on the
crank-
shaft.
30. Install the crankshaft
damper.
31. Install the water pump,
alter-
nator, fan pulley, and fan. Install
and adjust the drive belt.
32. Prime the oil pump by filling
either the inlet or outlet port with
engine oil. Rotate the pump shaft to
distribute the oil within the pump
body.
33. Install the oil pump.
Clean
and install the oil inlet tube
assembly.
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