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stnp
on
the
beanng
Journal
FIQ
A 29
If the clearance exceeds
the
wear
limit of 0 10
mm
00039
In
for the
main
beanngs
and and for the
big
end
beanngs
fit undersize
bearings
and
regrind
the crankshaft
to SUit
the undersize
bearings
Undersize
bearings
are
available
In
1 1000
mm
25 50 75
100 for
main
bearings
and 6
12 25 50 75 and 100 for the
big
end
bearings
Crankshaft and camshaft
timing
gears
Check the
sprockets
and the tlmll19 chain for
wear
and
replace
where necessary
Check the
run
out
of the camshaft
sprocket
as
shown
In
Fig
A 30 The
run
out
should
not
exceed the limit of
o 1
mm
0 043
In
Check the chain
tenslOner
and the chain gu Ide for
wear
and
replace
If necessary
Fig
A 31
Flywheel
Check the clutch
contact
area
of the
flywheel
for
damage
and
wear
and If necessary
re
alr
or
replace
the
flywheel
Check the
flywheel
for
run
out
uSing
a
dial gauge and
replace
the
flywheel
If the limit of 0 1
mm
0043
In
IS
exceeded
If the ring gear
IS
worn or
damaged
remove
the gear ring
by
heating
It to
about
150
2000
C
300
3900F
and
tapping
It
off Sometimes
It
might
be necessary
to
split
the ring gear With
a
chisel
In thiS
case
take
care
not to
damage
the
flywheel
Refit the
new
ring
gear
In reverse
order and cool
at
normal
air
temperature
ENGINE
Assembly
Apply
engine 011
to
all
sliding
or
rotating parts of the engine
I e
cylinder
walls pistons
bearings
gears
etc
and
renew
all seals
gaskets
and lock
plates
Place the valve spring
seat
In
poSition and fit the valve
gUide
With
the
011
seal
Assemble
the
valves
In
the
follOWing
order
Valve
Inner
and
outer
valve springs
spring
retainer
valve
cotter
halves and valve rocker
gUide
Compress
the valves
With
a
suitable valve compressor
Fig
A 32
when
fitting
the
cotter
ha lves
Fit the rocker
arms
and the valve rocker springs
The Spring
holders
are
combined With the rocker
pivot
bushes
Assemble the
pistons gudgeon
pinS piston rings and connecting
rods for
each
cylinder
Fig
A 34 and
A 35
and
place
the
bearing
shells
Into
the
main
bearing
hOUSings
and caps and the
connecting rods and caps
Lift the crankshaft
In
the
bearings
Tighten
down the
main
bearing
cap bolts
to
4 5
55
kgm
325
39 8 lb ft
Arrange
the
arrow
mark
on
the
bearing
cap
to
face
the front of the engine The
bearing
caps shou ld be
tightened
In
gradual
steps
In
three
or
four
stages
starting
at
the
centre
and
working
towards the outside Check the crankshaft end
playas
shown
In
Fig
A 36 which should be 005
015
mm
0002
00061n
Install the Side 011 seals
Into
the
rear main
bearing
cap
as
shown
In
Fig
A 37 Fit the
rear
011 seal uSing
special
tool
ST49370000
If the
Original
crankshaft
IS
used and the
contact
face for the 011
seal shows slgns of
wear
Install
a
shim
In
order
to
shift the
contact face
F
It
the
rear
end
plate
Fit the
flywheel
USing lock washers and
tighten
the
bolts to
95
105
kgm
68
7
75 9Ib ft
I
Flg
A
38
Install the
piston
and
connecting
rod
assembly
into the
correct
cylinder
from the
top
of the
cylinder
block
as
shown
In
Fig
A
39
with the
F
mark faCing
the
front
of
the
e g i
le
W
h
en
lnsertlng
the
piston
14
rings
ensure
that the
piston
ring gaps
are
opposite each other
and neither
parallel
to
or
at
nght
angles
to
the
gudgeon
pin
Fit
the
connecting
rods With the
numbers
on
the
same
Side
throughout
and
tighten
to
2 8
3 4
kgm
20 2
24 6 lb ft
Fig
A 40
Check the end clearance of the
big
end
bearings
which should be 0 20
030
mm
00079
00118
In
I
Fit the
cylinder
head
spreading
JOinting
compound
either Side
of the
gasket
Tighten
the
cylinder
head borts
In
the order
shown
In
Fig
A 42
to
a
tightening
torque of 5 0
60
kgm
36 2
43 4 Ib ft
Note there
are
3 types of bolts and each should go
In
the hole
It
came
out
of
Use
special
tool ST49010000
to
tlQhten
the
cylinder
head bolts
Fit the crankshaft
sprocket
and distributor drive and fit the 011
thrower
Fig
A 43
Install the timing chain
Fig
A 44 With the
timing
marks
on
the crankshaft and camshaft timing
sprockets
to the
right
hand Side COinCident With the timing marks
on
the
chain
There
must
be 42 chain links between the marks
on
the
chain
Fit the chain
gUide
to
the
cylinder
block and and Install the
chain
tensloner
FIt
a
new
011 seal
In
the front
cover
ThiS seal
should
always
be
replaced
when the front
cover IS
removed for
any
reason
I nstall the lower front
cover
and the upper front
cover In
that order With
a
gasket
between
cover
and
cylinder
block
The
gasket
should be coated With JOinting
compound
When
fitting
the upper
cover
check that
It
does
not
Interfere
With the
cylinder
head
gasket
Then check the
height
difference
between the upper faces of the
cylinder
block and the upper
cover
The difference should be less than 0 15
mm
0059
In
Fit the crankshaft
pulley
and the
water
pump Set the engine
at
T D C
position
on
the No 1
cylinder
In
Its
compressIOn stroke
Install the 011 pump and dlstnbutor drive
so
that the offset slot
IS In
the position shown
In
Fig
A 45
Fit the
fuel pump
water
Inlet
elbow
thennostat
hOUSing
engine
slinger
thennostat and
water
outlet elbow Refit the 011
strainer to
the bottom of the
cylinder
block and enclose the
engine
interior
by
refIning
the 011 sump coating the
new
gasket
With
JOinting
compound
on
both Sides
Fit
the
distributor
rear
engine
slinger
manifolds
and
carburettor
s
AdjUst
valve
tappets
Fig
A 46
to
020
mm
0008
In
for the Inlet valve
cold
and 025
mm
0010
In
for the exhaust valve
cold
and fit the rocker
cover
uSing
JOinting
compound
on
the
gasket
Fit the clutch and
gearbox assembly
the fuel hose
to
the front
part of the engine and the
high
tenSion
lead
to
the distributor
Remove
the
engine
from the mounting stand and
fit the
alternator bracket
alternator
engine
mountings
Ignition COil
011 filter
011 pressure SWitch
011 level
dipstick
and the
water
drain
plug
ENGINE
Installation
The installation
IS
carned
out
in
reverse
order
to
the removal
procedure
but the
follOWing
points
should be noted
Do not
tlQhten
the nuts and bolts
completely
until the engine
IS
resting flnnly
on
Its
mountings
Then
tlQhten
the nuts Fill the
engine With engine 011
and coolant
water
or
anti
freeze and the
g
o
with th
recommended
lubricant
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