Assembly
Fig. 10 Foil installation:
Fig. 11 Seal installation:
If main bearing inserts are being fitted to an out-of-round journal, ensure that the inserts are large enough for the maximum diameter of the journal. If inserts are fitted to the minimum diameter and the journal is out-of-round 0.001 inch or more, interference between bearing inserts and journal will result in rapid bearing failure.
1. Position crankshaft in cylinder block, then install main bearing cap Nos. 2, 3 and 4 with the replacement lower inserts in position.
2. Install the No. 1 main bearing cap, with a replacement lower insert, without the side seals. Tighten bolts and check endplay. If endplay is not within specification, install thrust washers as necessary to obtain the correct endplay.
3. Install No. 5 main bearing cap, with a replacement lower insert. Rotate crankshaft and ensure that it rotates smoothly.
4. Measure distance between the No. 1 main bearing cap and cylinder block, and No. 5 main bearing cap and cylinder block. If distance is .197 inch or less, use a .201 inch thick side seal. If distance is more than .197 inch, use a .212 inch thick seal.
5. Remove the No. 1 and No. 5 main bearing caps, then insert side seals in the main bearing cap slots, with grooves facing outward. Each side seal should protrude approximately 0.008 inch outward from cap. Lubricate contact surfaces of side seals lightly with clean engine oil.
6. Position a strip of suitable foil on each side of the main bearing caps. Torque caps to specifications.
7. Cut side seal ends so they protrude 0.020 - 0.028 inch above the cylinder block surface.
8. Using oil seal installation tool Mot. 788 or equivalent, for the seal at the flywheel/drive plate end and Mot. 789 or equivalent, for seal at the crankshaft sprocket end of cylinder block, install main bearing oil seals. If oil seal lip has excessively worn the contact surface at either end of the crankshaft, a .06 inch washer must be placed between installation tool and replacement oil seal to position seal further inward on crankshaft.
Fig. 12 Installing seals on liners:
Fig. 13 Piston, connecting rod and liner installation:
9. Install a replacement O-ring seal and plastic ring on each cylinder liner and ensure that O-ring is not damaged. If a connecting rod bearing upper insert is being fitted to an out-of-round journal, ensure that insert is large enough for the maximum diameter of the journal. If bearing insert is fitted to the minimum diameter and journal is out-of-round 0.001 inch or more, interference between the bearing insert and journal will result in rapid bearing failure. The bearing upper inserts have lubrication holes and the lower inserts do not. Ensure that the holes in upper insert are aligned with lubrication holes in the connecting rod.
10. Install piston, connecting rod and cylinder liner assemblies into cylinder block with bearing upper inserts and rods positioned on crankshaft journals. Ensure that cylinder liners are installed correctly. No. 1 cylinder liner assembly is adjacent to flywheel/drive plate end of block and liner flat surfaces are parallel. Ensure cylinder number stamped on each connecting rod and bearing cap is adjacent to the intermediate shaft side of block, and the combustion chamber in each piston crown faces toward the intermediate shaft side of block.
11. Install liner clamp tool Mot. 521-01 or equivalent, to cylinder head and torque bolts to 37 ft. lbs. to compress the liner seals to prevent liner seals from shifting.
12. Install each connecting rod bearing cap on its original connecting rod. Torque bearing cap bolts to 44-48 ft. lbs. Tap each connecting rod lightly (parallel to the crankshaft) and ensure that there is adequate clearance. Rotate crankshaft and ensure that the pistons, connecting rods and crankshaft function normally.
13. Install oil pump assembly and gasket. Ensure that locating dowels are in place. Torque oil pump retaining bolts to 30-33 ft. lbs.
14. Install oil pan and gasket. Torque bolts to 70-88 inch lbs.
15. Install water pump assembly. Continue to retain the timing belt tensioner plunger along with long strap and clip. Connect coolant hose and release strap, clip and timing belt tensioner.
16. Install clutch pilot bearing into end of crankshaft, if equipped. Seat bearing by gently tapping with a rubber mallet.
17. Apply Loctite 549, or equivalent, onto crankshaft to flywheel/drive plate mating surface.
18. Position flywheel/drive plate on to crankshaft and install holding tool Mot. 582 or equivalent. The original flywheel/drive plate self-locking bolts are not reusable. Use replacement bolts for each installation.
19. Lubricate threads of the replacement flywheel/drive plate bolts with Loctite 242, or equivalent, and torque flywheel bolts to 41 ft. lbs., and drive plate bolts to 52 ft. lbs. Bend locking plate tabs over flywheel/drive plate bolts. Remove holding tool.
Fig. 14 Crankshaft sprocket installation:
Fig. 15 Aligning intermediate shaft cover:
Fig. 16 Oil pump assembly installation:
Fig. 17 Adjusting intermediate shaft cover clearance:
20. Install washer, key and crankshaft sprocket. The chamfered side of washer must face cylinder block and chamfered edge of sprocket bore faces washer.
21. Install the intermediate shaft, clamp plate, gasket and cover. Loosely install retaining bolt and nut.
22. Install intermediate shaft oil seal and align cover with installation tool Mot. 790. If oil seal lip contact surface on the intermediate shaft has been excessively worn by the original seal, insert a .04 inch washer between the seal and installation tool to position seal further inward on shaft. The intermediate shaft cover retaining bolt extends through cylinder block and oil could seep out around bolt unless properly sealed.
23. Apply Loctite 242, or equivalent, to bolt threads, then install and tighten intermediate shaft cover retaining bolt and nut.
24. Install intermediate shaft sprocket, washer and bolt. Install sprocket with wider offset facing cylinder block.
25. Using holding tool Mot. 855 or equivalent, torque sprocket bolt to 37 ft. lbs.
26. Install oil pump drive shaft, gear, washer, and vacuum pump. Clearance between the intermediate shaft cover and the timing belt tensioner must be adjusted to prevent lateral movement of the timing belt when belt is tightened. The correct clearance is .004 inch. Adjust clearance by turning adjustment screw.
Fig. 18 Piston Protrusion Measurement:
Fig. 19 Dial indicator installation:
Fig. 20 Head gasket identification:
Fig. 21 Cylinder head locating tool installation:
27. Before the cylinder head can be installed, piston protrusion measurement must be done to determine correct size replacement gasket to be used. To determine piston protrusion, proceed as follows: The piston protrusion measurement, (A), procedure is necessary whenever major engine components have been replaced.
a. Rotate crankshaft one complete revolution and position No. 1 piston near (before) TDC of compression stroke.
b. Place thrust plate tool Mot. 252-01 or equivalent, on top of piston, then insert dial indicator Mot. LM in block gauge Mot. 251-01 or equivalent. Tighten screw clamp and place assembly on one side of thrust plate. Zero dial indicator pointer with stem located on cylinder block face. Place dial indicator stem on piston crown and rotate crankshaft clockwise until piston is at TDC. Do not press on tools or piston since incorrect readings will result.
c. Record stem travel distance indicated by the dial indicator pointer. Repeat measurement procedure with dial indicator placed on the opposite side of thrust plate. Record stem travel distance indicated by dial indicator pointer.
d. Calculate the average amount of piston protrusion from the two measurements. Note the following example: If protrusion at one side of piston is .033 inch and protrusion at the other side of piston is .043 inch, add .033 and .043 and divide by 2. Average piston protrusion is .038 inch.
e. Use the same procedure described to determine average amount of protrusion for the remaining pistons. Use piston that has the largest amount of average protrusion to determine required thickness of replacement cylinder head gasket.
f. If the largest amount of piston average protrusion is less than .038 inch, use gasket (A) that is .063 inch thick or has 2 holes. If between .038 and .041 inch, use gasket (B) that is .067 inch thick or has one hole. If more than .041 inch, use gasket (C) that is .071 inch thick or has three holes.
28. Remove cylinder liner clamps Mot. 588 and install cylinder head locating tool Mot. 720 or equivalent, at (A) for alignment.
29. Position replacement gasket onto cylinder block and ensure that gasket has the correct thickness for piston protrusion.
Fig. 22 Cylinder head tightening sequence:
Fig. 23 Piston to cylinder head clearance:
Fig. 24 Valve travel distance:
30. Position camshaft in cylinder head, then install cylinder head and gasket onto block. Torque cylinder head bolts in 4 steps in sequence shown as follows:
a. First, torque bolts to 22 ft. lbs.
b. Second, torque bolts to 37 ft. lbs.
c. Third, torque bolts to 70-77 ft. lbs.
d. Finally, torque bolts again to 70-77 ft. lbs. Remove tool Mot. 720 or equivalent. The cylinder head bolts must be retightened after engine is installed in vehicle. Operate engine for a minimum of 20 minutes. Allow engine to cool for a minimum of 2.5 hours, then loosen each cylinder head bolt (in sequence) 1/2 turn and then torque in sequence to 70-77 ft. lbs. For final torquing, torque bolts again in sequence to 70-77 ft. lbs.
31. Check piston-to-cylinder head clearance. Clearance must be greater than .023 inch for proper operation.
32. Select a valve and use the following procedure to measure clearance between valve face (when seated) and the corresponding piston crown:
a. Rotate crankshaft clockwise and move selected piston to BTDC position. Compress valve spring using valve spring compressor Mot. 382 or equivalent, and remove locks and spring.
b. Push down on valve stem and ensure that piston is near TDC position. Attach bracket tool Rou. 541 or equivalent, to an adjacent rocker arm shaft bearing pedestal with a bearing hold down bolt.
c. Attach dial indicator Mot. LM or equivalent to bracket tool and align it so that the stem rests on valve stem selected for measurement. With valve resting on piston crown, use dial indicator as a reference and rotate crankshaft to move piston up exactly to TDC position, then set dial indicator pointer to zero.
d. Lift valve up into its seat in the cylinder head and observe dial indicator valve travel distance between piston crown and valve seat. Record valve travel distance (C).
e. Calculate piston-to-cylinder head clearance according to the following procedure: Subtract valve recess (B) dimension, from valve travel distance (C) measured above. The result should be greater than .023 inch.
f. Note the following example: If intake valve recess is .036 inch, and exhaust valve recess is .034 inch, both valve recess dimensions are within the valve recess tolerance of 0.031 - 0.045 inch. The smallest valve recess dimension should always be used for the piston to cylinder head clearance calculation. Valve travel distance (C) is .061 inch, the clearance (D) equals (C) minus (B). (D) equals .061 inch minus .034 inch. (D) equals .027 inch and is an acceptable clearance.
g. Position valve spring over valve stem, compress spring with a compressor tool and install valve collets.
33. Install rocker arm shaft assembly into cylinder head. Torque shaft bearing hold-down bolts to specifications.
34. Install replacement camshaft oil seal, then measure camshaft endplay.
35. Install camshaft sprocket and retaining bolt. Using sprocket holding tool Mot. 855 or equivalent, torque camshaft sprocket bolt to 37 ft. lbs. Rotate camshaft until sprocket timing marks are at the 12 o'clock position.
36. Attach fuel injection pump mounting brackets and pump to cylinder head with the retaining bolts.
37. Remove inspection plug from cylinder block and install TDC rod Mot. 861 or equivalent into hole against crankshaft counterweight. Rotate crankshaft clockwise until TDC rod enters TDC slot in the crankshaft countershaft.
Fig. 25 Retaining timing mark position:
Fig. 26 Timing mark index location:
Fig. 27 Injector clamp installation:
38. Install sprocket holding tool Mot. 854 or equivalent, to retain camshaft and fuel injection pump sprocket timing marks in place.
39. Install timing belt on the sprockets. There should be a total of 19 timing belt cogs (teeth) between camshaft sprocket timing mark and the fuel injection pump sprocket timing mark. Temporarily position timing belt cover over the sprockets and check camshaft and fuel injection pump sprocket timing marks with indexes on cover.
40. Remove timing belt cover and sprocket holding tool Mot. 854 or equivalent.
41. Adjust timing belt tension as follows:
a. Ensure that timing belt is correctly positioned around all the sprockets and loosen belt tensioner bolts 1/2 of a turn (maximum). The spring loaded belt tensioner, in contact with belt, will automatically adjust to the correct position.
b. Tighten tensioner bolts and remove TDC rod Mot. 861 or equivalent, and install inspection plug into cylinder block.
c. Rotate crankshaft clockwise, two complete revolutions and loosen timing belt tensioner bolts 1/2 of a turn, then tighten.
d. Measure timing belt tension. Belt deflection should be .118 to .197 inch. Install timing belt cover.
42. Install replacement copper washers and heat shields into cylinder head injector bores.
43. Install injectors in their original bores in the cylinder head. Place injector clamps over injectors and install retaining washers and nuts. Torque clamp nuts to 12.5 ft. lbs.
44. Install glow plugs and connect injector fuel return hoses with replacement washers at each fitting.
45. Install glow plug wire harness. Do not install injector high pressure fuel pipes at this time.
46. Apply Loctite 549 or equivalent to crankshaft sprocket mating surface on the crankshaft pulley. Position crankshaft pulley on end of crankshaft.
47. Insert pins through the pulley and into the crankshaft sprocket.
48. Apply a small amount of Loctite 242 or equivalent to the threads of crankshaft pulley bolt.
49. Install crankshaft pulley washer and bolt. Torque bolt to 96 ft. lbs.
50. Install water pump pulley and fan assembly.
51. Install starter, alternator, drive belts and, if equipped, A/C compressor. Check belt tension.
52. Install intake and exhaust manifolds with replacement gaskets.
53. Install turbocharger with replacement nuts. Connect all hoses and the oil supply line.
54. Install thermostat housing assembly with a replacement gasket.