Part Two
Fit The Ring Gear And Flexible Drive Plate Assembly
Drive Plate & Components:
1. Fit the shim and crankshaft adaptor plate to the crankshaft flange noting the previously marked identification lines and secure in position with the six socket head bolts. Do not fully tighten the bolts at this stage.
2. Fit the ring gear assembly, hub aligner, flexible drive plate noting the previously marked identification lines and secure in position with the four bolts and clamping ring. Do not fully tighten the bolts at this stage.
3. To ensure that there is no distortion to the flexible drive plate when bolted to the torque converter, check the setting height of the drive plate as follows.
4. To prevent excessive clearance, a shim is fitted between the crankshaft drive flange and crankshaft adaptor plate. The setting height, dimension A, is measured between the front face of the ring gear drive plate and engine cylinder block to gearbox mating face, a dimension of 8.08-8.20 mm (0.318-0.323 in) is to be maintained. Should this dimension not be achieved, a selection of shims in progressive thicknesses is available. Select the appropriate shim to maintain the dimension.
Part NO. Dimension (MM)
FRC 7084 1.20-1.25
FRC 7085 1.30-1.35
FRC 7086 1.40-1.45
FRC 7087 1.50-1.55
FRC 7088 1.60-1.65
FRC 7089 1.70-1.75
FRC 7090 1.80-1.85
FRC 7091 1.90-1.95
FRC 7092 2.00-2.05
FRC 7093 2.10-2.15
Drive Plate Mounting Dimensions:
Key to Dimensions:
1. Crankshaft flange.
2. Shim.
3. Crankshaft adaptor flange.
4. Drive plate and ring gear assembly.
5. Hub aligner.
6. Flexible drive plate.
7. Clamp ring.
5. Remove the four bolts clamp ring flexible drive plate hub aligner and ring gear assembly.
6. Remove the six socket head bolts and crankshaft adaptor.
7. Fit the appropriate shim, refit the adaptor and six socket head bolts, tighten to 77-90 Nm (57-66 ft lb). These bolts should be coated with Loctite(r) 270 or equivalent, prior to assembly.
8. Fit the ring gear assembly, hub aligner, flexible drive plate and clamp ring.
9. Coat the threads of the four securing bolts with Loctite(r) 270 prior to assembly, fit the bolts and tighten to 35-46 Nm (26-34 ft lb).
Fit Cylinder Heads
Cylinder Head Gasket:
1. Fit new cylinder head gaskets with the word TOP uppermost. Do NOT use sealant.
Cylinder Head Bolts:
2. Locate the cylinder heads on the block dowel pins.
3. Clean the threads of the cylinder head bolts then coat them with Thread Lubricant-Sealant Loctite(r) 572.
Cylinder Head Bolt Torque Sequence:
4. Locate the cylinder head bolts in position as illustrated and fit dipstick tube.
Long bolts - 1,3, and 5.
Medium bolts - 2,4,6,7,8,9, and 10.
Short bolts - 11,12,13, and 14.
NOTE: Left-hand cylinder head illustrated. Arrow points to front of vehicle.
5. Tighten the cylinder head bolts a little at a time in the sequence shown.
Outer row 54-61 Nm (40-45 ft lb)*
Center row 88-95 Nm (65-70 ft lb)*
Inner row 88-95 Nm (65-70 ft lb)*
* Thread Lubricant-Sealant Loctite(r) 572
6. When all bolts have been tightened, re-check the torque values.
Fit tappets, push rods, and rocker assemblies
Lifters & Pushrods:
1. Fit the tappets and push rods to their original locations. Ensure that the tappets move freely in their respective bores. Before fitting the tappets immerse them in clean engine oil to reduce tappet noise when the engine is first started after the overhaul.
2. The rocker shafts are handed and must be fitted correctly to align the oilways.
Rocker Shaft Positioning:
3. Each rocker shaft is notched at one end and on one side only. The notch must be uppermost and towards the front of the engine on the right hand side, and towards the rear on the left hand side.
Rocker Shaft Bolts:
4. Fit the rocker shaft assemblies. Ensure that the pushrods engage the rocker cups. Tighten the bolts to 34-40 Nm (25-30 ft lb). It should be noted that tappet noise can be expected on initial starting up after an overhaul due to oil drainage from the tappet assemblies or indeed if the vehicle has been standing over a very long period. If excessive noise should be apparent after an overhaul, the engine should be run at approximately 2,500 rpm for a few minutes (subject to the following caution), when the noise should be eliminated.
CAUTION: Do not exceed 1,000 rpm for 15 seconds when first starting the engine, otherwise the crankshaft rear oil seal will be damaged.
Fit The Intake Manifold
Intake Manifold Gasket:
1. Apply Hylomar SQ32M sealing compound, or equivalent, to the notches formed between the cylinder head and block,
2. Locate the NEW seals in position with their ends engaged in the notches formed between the cylinder heads and block.
Intake Manifold Gasket:
3. Apply Hylomar SQ32M sealing compound, or equivalent, on the corners of the cylinder head, manifold gasket and manifold, around the water passage joints.
4. Fit the manifold gasket with the word FRONT to the front and the open bolt hole at the front R/H side.
5. Fit the gasket clamps but do not fully tighten the bolts at this stage.
6. Locate the manifold on to the cylinder head.
7. Clean the threads of the manifold securing bolts.
Intake Manifold Bolts:
8. Fit all the manifold bolts and tighten them a little at a time, evenly, alternate sides working from the center to each end and finally tighten to 34-41 Nm (25-30 ft lb).
9. Tighten the gasket clamp bolts to 14-20 Nm (10-15 ft lb).