Part One

NOTE: Be sure all parts are clean before assembly.

Fit Crankshaft, Main Bearings, and Rear Oil Seal

1. Locate the upper main bearing shells into the cylinder block. These must be the shells with the oil holes and oil grooves.
2. Locate the flanged upper main bearing shell in the center position.
3. Lubricate the crankshaft main bearing journals and bearing shells with clean engine oil and lower the crankshaft into position.
4. Lubricate the lower main bearing shells and fit numbers one to four main bearing caps and shells only, leaving the bolts finger tight at this stage.

Rear Main Cap Side Seals:

5. Fit the cross shaped side seals to the grooves each side of the rear main bearing cap. Do not cut the side seals to length, they must protrude 1.5 mm (0.062 in) approximately above the bearing cap parting face.
6. Apply Hylomar SQ32M jointing compound, or equivalent, to the rearmost half of the rear main bearing cap parting face or, if preferred, to the equivalent area on the cylinder block as illustrated.
7. Lubricate the bearing half and bearing cap side seals with clean engine oil.
8. Fit the bearing cap assembly to the engine. Do not tighten the fasteners at this stage but ensure that the cap is fully home and squarely seated on the cylinder block.
9. Tension the cap bolts equally by one-quarter turn approximately then back off one complete turn on each bolt.

Rear Main Seal Guide:

10. Position the seal guide RO 1014 on the crankshaft flange.

CAUTION: Do not handle the oil seal lip. Visually check that it is not damaged and ensure that the outside diameter remains clean and dry.

11. Ensure that the oil seal guide and the crankshaft journal are scrupulously clean, then coat the seal guide and oil seal journal with clean engine oil.

NOTE: The lubricant coating must cover the seal guide outer surface completely to ensure that the oil seal lip is not turned back during assembly. Position the oil seal, lipped side towards the engine, on to the seal guide. The seal outside diameter must be clean and dry.

12. Push home the oil seal fully and squarely by hand into the recess formed in the cap and block until it contacts the machined step in the recess. Withdraw the seal guide.

Main Cap Bolts:

13. Tighten the main bearing cap bolts to:
Main cap bolts (except rear) 68-75 Nm (50-55 ft lb)
Rear main cap bolts 88-95 Nm (65-70 ft lb)

14. Using a feeler gauge or a dial indicator check the crankshaft end-float, 0.10-0.20 mm (0.004-0.008 in).

CAUTION: Do not exceed 1,000 engine rpm for 15 seconds when first starting the engine, otherwise the crankshaft rear oil seal will be damaged.

Fit Connecting Rods And Pistons
1. Position the applicable crankshaft journal at bottom dead center (BDC).

Connecting Rod ID:

2. Place the bearing upper shell in the connecting rod.
3. Retain the upper shell by screwing the guide bolts 605351 onto the connecting rods.
4. Insert the connecting rod and piston assembly into its respective bore, noting that the domed shape boss on the connecting rod must face towards the front of the engine on the right hand bank of cylinders and towards the rear on the left hand bank. When both connecting rods are fitted, the bosses will face inwards towards each other.

Piston Ring Placement:

5. Position the oil control piston rings so that the ring gaps are all at one side, between the piston pin and piston thrust face. Space the gaps in the ring rails approximately 25 mm (1 in) to each side of the expander ring joint.
6. Position the compression rings so that their gaps are on opposite sides of the piston between the piston pin and piston thrust face.

Fitting Piston To Block:

7. Using a piston ring compressor, locate the piston into the cylinder bore, until the piston crown is just below the cylinder block top face.

Connecting Rod Tool:

8. Pull the connecting rods on to the crankpins using the guide rods. Use extreme care when pulling the pistons down their respective bores to prevent scratching the crank pins.
9. Place the bearing lower shell in the connecting rod cap.
10. Locate the cap and shell onto the connecting rod, noting that the rib on the edge of the cap must be towards the front of the engine on the right hand bank of cylinders and towards the rear on the left hand bank.
11. Check that the connecting rods move freely sideways on the crankshaft. Tightness indicates insufficient bearing clearance or a misaligned connecting rod.

Measuring Connecting Rod End-float:

12. Check the end-float between the connecting-rods on each crankshaft journal. Clearance limits: 0.15-0.37 mm (0.006-0.015 in).
13. Tighten the connecting rod nuts to 47-54 Nm (35-40 ft lb).
14. Fit the oil strainer and joint washer.

Fit Camshaft, Timing Chain, And Sprocket

Fitting Camshaft:

1. Lubricate the camshaft journals and carefully insert the camshaft into the cylinder block.
2. Turn the crankshaft to bring number one piston to TDC.

Timing Gear Alignment Marks:

3. Temporarily fit the camshaft sprocket with the marking F or FRONT outward.
4. Turn the camshaft until the mark on the camshaft sprocket is at the six o'clock position, then remove the sprocket without disturbing the camshaft.
5. Encircle the sprockets with the chain keeping the timing marks aligned.

Timing Chain And Gears:

6. Engage the sprocket assembly on the camshaft and crankshaft key locations and check that the camshaft key is parallel to the shaft axis to ensure adequate lubrication of the distributor drive gear.

Shaft & Key Dimension:

CAUTION: The space between the key and keyway acts as an oil-way for lubrication of the drive gear. Ensure that the key is seated to the full depth of the keyway. The overall dimension of shaft and key must not exceed 30.15 mm (1.187 in). Dimension A.

Distributor Drive Gear:

7. Check that the timing marks line up and fit the spacer with the flange to the front.
8. Fit the distributor drive gear ensuring that the annular grooved side is fitted to the rear, that is towards the spacer.
9. Secure the drive gear and camshaft sprocket assembly with the bolt and washer and tighten to 54-61 Nm (40-45 ft lb).