Chain Removal”. Remove the crankshaft sprocket key.
15. Remove any ridge and/or carbon deposits from the upper end of the cylinder bores. Move the piston to the bottom of its travel and place a cloth on the piston head to collect the cuttings. Remove the cylinder ridge with a ridge cutter. Follow the instructions furnished by the tool manufacturer. Never cut into the ring travel area in excess of 1/32 in. when removing ridges. After the ridge has been removed, remove the cutter from the cylinder bore. On a flywheel for a manual-shift transmission, remove the clutch pressure plate and disc.
16. Remove the flywheel and rear cover plate. Remove the clutch pilot bushing (Fig. 97) if necessary.
17. Invert the engine. Remove the oil pan and discard the gaskets and seals.
18. Remove the oil pump and inlet tube as an assembly. Remove the intermediate drive shaft. Discard the oil pump gasket.
19. Make sure all connecting rods and caps are marked so that they can be installed in their original locations. Turn the crankshaft until the connecting rod being removed is down. Remove the rod cap.
20. Push the connecting rod and piston assembly out the top of the cylinder with the handle end of a hammer. Avoid damage to the connecting rod journal or the cylinder wall when removing the piston and rod.
21. Remove the bearing inserts from the connecting rods and caps. Install the rod caps on the con-necting rods from which they were removed.
22. Remove the main bearing caps.
23. Carefully lift the crankshaft out of the cylinder block so that the thrust bearing surfaces are not damaged. Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.
24. Remove the rear journal oil seal from the block and rear bearing cap.
25. Remove the main bearing Inserts from the block and bearing caps. Install the main bearing caps in their original positions.
26. Remove the camshaft thrust plate. Carefully remove the camshaft by pulling it toward the front of the engine. Use caution to avoid damaging the journals and lobes.
27. If necessary, remove the camshaft rear bearing bore plug (Fig. 68). Remove the camshaft bearings (Fig. 71).
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ENGINE ASSEMBLY
I. Remove the glaze from the cylinder bores by following the instructions of the tool manufacturer.
2. Invert the engine on the work stand.
3. Position the new camshaft bearings at the bearing bores, and press them in place with the tool shown in Fig. 71. Align the oil holes in the cylinder block when the bearings are installed. Be sure the camshaft front bearing is installed O.OO5— O.OlO in. below the front face of the cylinder block (Fig. 69).
4. Clean out the camshaft rear bearing bore plug recess thoroughly. Coat the flange of a new plug with oil-resistant sealer and install it with the cup side facing out (Fig. 70). Drive the plug In until It Is slightly below the chamfer in the bore.
5. Oil the camshaft journals and apply Lubriplate to all lobes, then carefully slide it through the bearings.
6. Clean the rear journal oil seal groove and the mating surfaces of the block and rear main bearing cap. Preform the new seal by hand to the approxi-mate radius of the cap.
7. Insert the seal in the oil seal groove, seating the centre of the seal first and allowing the seal to extend equally on both ends. Press the seal down firmly with the thumb at the centre of the seal, then press both ends of the seal into the groove, working from the ends to the centre.
8. Position the seal forming tool as shown in Fig. 90 and complete the seal installation. After Installation, cut the ends of the seal flush.
9. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize bearings. Be sure the bearing Inserts and bearing bores are clean. Foreign material under the inserts may distort the bearing and cause a failure.
Place the upper main bearing Inserts In position in the bore with the tang fitting in the slot pro-vided.
10. Install the lower main bearing inserts in the bearing caps.
11. Carefully lower the crankshaft into place. Be careful not to damage the bearing surfaces.
12. Check the clearance of each main bearing following the procedure under “Main Bearing Replacement”.
13. After the bearings have been fitted, apply a light coat of engine oil to the journals and bearings.
14. Install a new journal seal in the cap (Fig. 84) by following steps 6, 7 and 8. Apply a thin coating of oil-resistant sealer to the rear main bearing cap at
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