Crankcase, Crankshaft, Main Bearings & Flywheel

3.INSTALLATION

a)THE MAIN BEARINGS AND CRANKSHAFT

1.Wipe clean the upper bearing half supports in the crankcase, wipe the bearing faces with oil and install the upper bearing halves with the locating nibs in position.

2.Wipe the crank pins and journals clean and lay the crankshaft in position.

3.Coat the lower bearing halves and caps in oil and assemble the bearings to the caps.

4.Install the bearing caps and bearings in their correct positions and secure with the capscrews. Tighten the capscrews to the torque detailed in SPECIFICATIONS and install the lockwires if the capscrew heads are drilled.

NOTE: If it is necessary to replace one of the bearing cap capscrews with a “Place” bolt, both must be replaced as the heads of “Place” bolts are not drilled.

5.Pull the connecting rods down on to the crankshaft, lubricate the bearing faces and assemble the caps in the correct positions. Secure with the capscrew, tightening them to the torque detailed in SPECIFICATIONS.

NOTE: When correctly positioned, the main bearing half will stand out 1/32” either side above the cap surface and engage inside the crankcase half bore. Failure to position correctly will result in bearing halves being out of line when cap bolts are torqued down.

6.Press a new oil seal into the rear oil seal retainer with the lip towards the front of the engine. The seal must be pressed hard against the shoulders of the retainer to ensure squareness.

7.Use jointing compound and fit a new horseshoe gasket to the rear face of the crankcase, lining up the holes in the gasket with the bolt holes.

8.Apply a light coating of grease to the oil seal and fit it over the end of the crankshaft, taking care not to damage the lip of the seal. Use a seal assembly sleeve for this operation if possible. Ensure that the garter spring is fitted and in position. Locate the retainer on the dowels.

9.Fit the five retainer bolts and tighten to the correct torque by stages to ensure even seating on the gasket.

NOTE: The bottom face of the retainer, after assembly, must align with the face of the crankcase within 0.020”.

10.Trim the rear oil seal retainer gasket flush with the bottom of the crankcase.

11.Assemble the crankcase front cover.

12.Assemble adapter plate on crankcase using four bolts and apply liquid gasket.

13.Assemble the flywheel to the crankshaft (a & b).

14.Install the lubricating oil pump.

15.Use liquid gasket (loctite 584) between oil pan and adapter plate joint.

16.Fill the crankcase with the correct grade of oil to the level mark on the dipstick.

Cylinder Block

INSPECTION & REPAIR :

Thoroughly clean the cylinder block. Remove the oil sludge deposits on the inner surfaces of the cylinder block. Remove the old gasket materials from the cylinder head, thermostat, water pump, rear oil seal, oil pan and oil filter mating faces. Check the cylinder head mating face for warpage using a straight edge and a feeler gauge. If inspection proves it necessary, remove the studs and cylinder head guide dowels. While installing the cylinder head guide dowels, ensure that the dowel projects 5.85 mm (0.23 in) above the face of the block. Clean the lubricating oil galleries using wire brush. While installing expansion plugs, ensure that shellac/sealer is present around the edges as well as inside the plugs.

Conditioning Schedule

GENERAL :

After the installation of new sleeves, pistons or piston rings, the engine must be run-in before being operated at full speed and load. The first phase of running-in must be gentle enough to prevent excessive pressure and temperatures. But too gentle operation may result in cylinder wall glazing due low combustion temperatures. Improper runningin procedure may result in shorter engine life, loss of power and high oil consumption.