Engine Assembly

Fig. 13 Piston and connecting rod assembly:

PISTON & CONNECTING ROD

1. Install the piston pin clip in the groove on one side of the piston.
2. Place the connecting rod in the piston and align the hole of the connecting rod with the hole of the piston.
3. Insert the piston pin with the installer (49 0223 061) until the piston pin clip can be fitted. Preheat the piston if tight.
4. Fit the piston pin clip in the groove. Care must be taken during the installation that relative positions of the oil hole on the connecting rod big end and the F mark on the piston are in accordance with Fig. 13.

PISTON RING

1. Fit the expander in the bottom ring groove and install the oil ring on it with a suitable installer.
2. Install the second ring, then the top ring. Be sure to install the rings with the inscription mark upward as the faces of the top and second rings are tapered. Do not expand the rings more than necessary to install. Also be careful not to burr the piston with the end of the rings.

PISTON & CONNECTING ROD ASSEMBLY

1. Place the piston rings at about 120° apart so that the gap is not located on the thrust side and the piston pin side.
2. Lubricate the entire assembly with engine oil.
3. Using a suitable piston installer, insert the piston and connecting rod assembly from the top of the cylinder block by tapping the piston lightly with a plastic hammer. Insert the piston to the cylinder so that F mark on the piston is directed to the front of the engine.
4. Invert cylinder block.
5. Fit connecting rod bearing halves into their respective locations.

Fig. 14 Install thrust washer into engine block:

CRANKSHAFT

1. Clean contact surfaces of cylinder block, main bearings and crankshaft.
2. Fit the five sets of main bearings properly to cylinder block and bearing caps respectively.
3. Fit the half of the thrust washers to the cylinder block with oil grooved surface facing crankshaft thrust side, Fig. 14.
4. Lubricate main bearing surfaces with engine oil.
5. Place crankshaft in cylinder block, being careful not to drop thrust washers.

Fig. 15 Install rear oil seal:

6. Fit oil seal to rear end of crankshaft after applying grease to seal lip, Fig. 15.

Fig. 16 Installing side seal:

7. Insert the rod-shaped oil seals (side seals) into grooves on both sides of rear main bearing cap. The side seals should be installed as shown in Fig. 16.
8. Fit the half of the thrust washers to the rear main bearing cap with grooves toward crankshaft thrust side.
9. Install main bearing caps. The main bearing caps are marked with a number which shows the order of their arrangement.
10. Tighten bolts to 61-65 ft.lbs. (8.4-9.0m-kg).

Timing Chain Installation:

TIMING CHAIN, OIL PUMP DRIVE CHAIN & SPROCKETS

1. Place timing chain on crankshaft and camshaft sprockets with talley (timing) marks and nickel-plated chain links aligned.
2. Being careful not to alter relation between sprockets and chain, fit crankshaft sprocket onto crankshaft so that sprocket is flush with end of crankshaft.
3. Install key on oil pump shaft.

NOTE: Wire chain and camshaft sprocket together to maintain timing mark alignment.

4. Fit oil pump drive chain onto oil pump and crankshaft sprockets. Slide in crankshaft sprocket, aligning key on oil pump shaft with keyway of pump sprocket.

Fig. 18 Checking oil pump drive chain stretch:

Fig. 19 Installing oil pump drive chain adjusting shims:

5. Check slack of drive chain by pressing a finger as shown in Fig. 18. If slack exceeds 0.157 in. (4.0 mm), install adjusting shims between cylinder block, Fig. 19, and oil pump body and adjust slack to be within 0.157 in. (4.0 mm). The thickness of the adjusting shims is 0.006 in. (0.15 mm).
6. Tighten nut for oil pump sprocket to 22-25 ft.lbs. (3.0-3.5 m-kg) and bend tab of lockwasher.
7. Align keyways of crankshaft and sprocket and install the key.

Fig. 20 Installing connecting rod cap. Note identification numbers must be on same side:

CONNECTING ROD BEARING CAP

1. Fit connecting rod bearing halves into their respective caps.
2. Lubricate connecting rod bearing surfaces with engine oil.
3. Install caps to the connecting rods, ensuring identification numbers are matched, Fig. 20.
4. Torque bolts 36-40 ft.lbs. (5.0-5.5 m-kg).
5. Turn crankshaft and ensure rotation is light and smooth.

Fig. 21 Installing O-ring:

OIL PUMP & STRAINER

1. Fit O-ring to outlet hole on oil pump and install oil pump to cylinder block, aligning dowel pins, Fig. 21.
2. Tighten attaching bolts.
3. Place O-ring on oil pump and install oil strainer to the oil pump. Tighten the nuts.

Fig. 22 Installing chain adjuster guide:

CHAIN GUIDE STRIP & VIBRATION DAMPER

1. With adjuster spring compressed fully, install chain adjuster guide (49 0660 260) to adjuster, Fig. 22.
2. Do not remove tool until chain adjustment is finished.
3. Install and tighten attaching bolts, while holding tool in place. Do not remove plate until timing chain is adjusted.
4. Install chain vibration damper to cylinder block and tighten attaching screws.
5. Install chain guide strip. Do not tighten attaching screws as tension is adjusted by the strip, which is explained under ``Adjusting Timing Chain.''

TIMING CHAIN COVER

1. Fit oil thrower to crankshaft with edge turned outward.
2. Fit oil deflector and oil seal into timing chain cover, then fill oil seal lip with grease.
3. Place gaskets on cylinder block and install chain cover, aligning dowel pins. Tighten the bolts.
4. Cut off excess gaskets along mounting surfaces of oil pan and cylinder head.

OIL PAN, FLYWHEEL & CLUTCH

1. Before installing oil pan, make a final internal inspection.
2. Apply a thin coat of gasket paste onto oil pan.
3. Place a new gasket on cylinder block.
4. Install oil pan and tighten bolts and nuts little by little in turn.
5. Install flywheel and clutch.

CRANKSHAFT PULLEY

1. Lock flywheel with brake (49 0221 030A) or other suitable tool.
2. Install crankshaft pulley to crankshaft so that key groove of pulley aligns with key on crankshaft.
3. Tighten pulley bolt to 101-108 ft.lbs. (14.0-15.0 m-kg).

CYLINDER HEAD

1. Hold the camshaft sprocket and chain securely and invert the cylinder block.
2. Place the sprocket and the chain on the top of the chain guide strip and the vibration damper. Ensure that alignment marks of the camshaft sprocket and the chain are aligned properly.
3. Place a new gasket on the cylinder block.
4. Position the cylinder head on the cylinder block, aligning the dowels.

CAMSHAFT

1. Fit the three sets of the camshaft bearings properly to the cylinder head and the bearing caps respectively.
2. Lubricate the bearing surfaces with engine oil.
3. Install the camshaft to the sprocket, aligning the key and fit the camshaft journals onto the respective bearings.

Fig. 23 Rocker arms & shaft assemblies:

ASSEMBLING ROCKER ARMS

Assemble the rocker arms in the formation shown in Fig. 23. Care must be taken on the following points:
1. The rocker arm shaft supporters are interchangeable for intake and the exhaust valves, however, the intake and exhaust rocker arms are not interchangeable.
2. The rocker arm shafts for the intake and the exhaust valves are not interchangeable. Two shafts are installed on the intake side and one on the exhaust side. The two shafts for the intake side are interchangeable.

Fig. 24 Rocker arm shafts:

3. When installing rocker arm shafts on intake side, ends with longer distance between oil hole and tip are turned toward inside each other, as shown in Fig. 24.
4. The center bearing cap is installed with the oil hole facing the intake side.
5. The oil pipe is installed with the oil ejection hole facing the camshaft. In order to avoid vibration of the pipe after it has been installed, the O-ring on the pipe is pressed into the hole for the pipe on the center bearing cap.

INSTALLING ROCKER ARM ASSEMBLY

1. Position rocker arm assembly on the cylinder head, with dowels properly aligned.
2. Tighten the cylinder head bolts temporarily.

Fig. 25 Rocker arm offset:

3. Move the rocker arm supporters and offset each of the rocker arms 0.04 in. (1 mm) from the valve stem center as shown in Fig. 25.

Fig. 1 Cylinder head bolt tightening sequence:

4. Tighten the cylinder head bolts according to the sequence shown in Fig. 1. "Cold" engine torque specification is 59 - 64 ftlb (82 - 88 Nm). "Warm" engine specification is 69 - 72 ftlb (95 - 100 Nm).
5. Lock the flywheel with the brake (49 0221 030A) and tighten the camshaft sprocket locknut to 51-58 ft.lbs. (7.0-8.0 m-kg) with the spanner (49 0164 631A). Bend the tab of the lock washer.
6. Aligning the key groove with the pin, install the distributor drive gear to the camshaft. Tighten the locknut to 51-58 ft.lbs. (7.0-8.0 m-kg) and bend the tab of the lock washer.

Fig. 26 Adjusting timing chain tension:

ADJUSTING TIMING CHAIN

1. Slightly rotate the crankshaft in normal direction of rotation.
2. Press the top of the chain guide strip with a lever through the hole of the chain cover and tighten the guide strip attaching screws with a screwdriver inserted through two holes on the timing chain cover, Fig. 26.
3. Remove the guide which was installed to the chain adjuster. The timing chain now has the proper tension and no further manual adjustment is required.
4. Install the blind plugs and aluminum washers to the two holes on the timing chain cover.
5. Install the blind cover and gasket for the chain adjuster to the chain cover and tighten the nuts.

MANIFOLD & CARBURETOR ASSEMBLY

1. Place the gasket on the cylinder head and install intake manifold and carburetor assembly.
2. Tighten the attaching nuts.
3. Connect the vacuum tube to the carburetor.
4. Connect the water hose to intake manifold.
5. Connect the water bypass hose to the thermostat case.
6. Connect the ventilation hose to the ventilation valve at intake manifold.

ROCKER ARM COVER

1. Apply rubber sealer to the semicircular oil seals and fit them, with the OUT mark facing outward, to the front and rear of the cylinder head.
2. Place the gasket on the cylinder head.
3. Install the rocker arm cover and tighten the attaching nut to 0.15-0.2 m-kg (1.1-1.4 ft.lbs.).

FINAL ASSEMBLY

1. Install thermostat.
2. Install water pump.
3. Install fan and pulley.
4. Install oil filter.
5. Install air pump.
6. Install alternator.
7. Install distributor.