Assembly

Fig. 43 Piston & Connection Rod Alignment Mark Locations:

1. Refer to DISASSEMBLY to assemble, noting the following:
2. Assemble the piston and the connecting rod with the R or L mark and the connecting rod locating pin positioned upward as shown in Fig. 43.
3. Apply clean engine oil to the piston rings and piston.

Fig. 44 Position Of Upper & Lower Oil Control Rings:

4. When installing the three piece oil rings, ensure both rails are expanded by the spacer tangs as shown in Fig. 44, and oil rings turn smoothly in both directions. The rings must be installed with the ``R'' marks upward. The second ring must be installed with the scraper face downward.

Fig. 45 Clocking Positions Of Piston Rings:

5. Install the second compression ring, then the first. Position the ring end gaps of each ring as shown in Fig. 45.

Fig. 46 Installation Of Oil Jets:

6. Apply thread locking compound to the oil jet threads, then torque oil jets to 26-43 inch. lbs., Fig. 46.
7. Remove any foreign material and oil from the journals and main bearings, then install the upper bearings and upper thrust bearings into cylinder block. The grooved main bearings are installed in the upper cylinder block. No. 4 bearing is wider than the other bearings.

Fig. 47 Cylinder Block Retaining Bolt Specifications:

8. Measure the length of crankshaft cap bolts, Fig. 47. Maximum length on main bolts ``A and B'' is 5.45 inch, maximum length on sub bolts ``C'' is 4.76 inch, replace bolts if measurements exceed specifications. ``A'' bolts have a mark ``4'' on each bolt head, ``B'' bolts have a mark ``I'' on each bolt head.

Fig. 48 Application of Silicone Sealant To Lower Half Of Block:

Fig. 49 Tightening Sequence For "A & B" Bolts:

Fig. 50 Tightening Sequence For "C" Bolts:

Fig. 51 Application Of Paint Marks For Additional Tightening:

Fig. 52 Tightening Sequence For Outer Cylinder Block Bolts:

9. Install cylinder block halves as follows:
a. Apply clean engine oil to bolt threads and seat faces of the crankshaft cap bolts.
b. Apply a continuous bead of silicone sealant to the contact surface as shown in Fig. 48. The lower cylinder block must be secured within five minutes after sealant is applied.
c. Torque the ``A and B'' bolts in two or three steps in sequence shown in Fig. 49, to 17-18 ft. lbs.
d. Torque the ``C'' bolts in two or three steps in sequence shown in Fig. 50, to 13-15 ft. lbs.
e. Apply a paint mark to the bolt shoulders and lower cylinder block for reference Fig. 50.
f. Torque ``A'' bolts in sequence shown in Fig. 49 an additional 80°, Fig. 51.
g. Torque ``B'' bolts in sequence shown in Fig. 49 an additional 70°.
h. Torque ``C'' bolts in sequence shown in Fig. 50 an additional 60°.
i. Torque ``A'' bolts in sequence shown in Fig. 49 an additional 80°, Fig. 51.
j. Torque ``B'' bolts in sequence shown in Fig. 49 an additional 70°.
k. Torque ``C'' bolts in sequence shown in Fig. 50 an additional 60°.
l. Install the remaining bolts shown in Fig. 52, then torque the bolts in the sequence shown to 14-16 ft. lbs.
10. Inspect the crankshaft endplay, endplay measurement should be between 0.0031-0.0111 inch. Maximum should not exceed 0.013 inch. If the endplay exceeds the maximum limit, grind the crankshaft and install oversize thrust bearings or replace the crankshaft and thrust bearings.
11. Install the connecting rod and pistons assemblies with the engine in the vertical position (crankshaft is straight up and down). Piston installation is easier with the crankshaft at BTDC. Insert the piston assemblies into the cylinder block with the ``L'' mark (left bank) and the ``R'' mark (right bank) stamped on the side of the piston near the pin, facing the front of the engine.
12. Tighten connecting rod cap bolts as follows:
a. Torque cap bolts to 16-19 ft. lbs.
b. Apply a paint mark to the bolt shoulder and cap for reference, then tighten an additional 90°.
c. Tighten all bolts an additional 90°.