the rear of the top mating surface (Fig. 84). Do not apply sealer to the area forward of the oil slinger groove. Install the rear main bearing cap and the remainder of the caps, except the thrust bearing cap (No. 3 bearing). Be sure that the main bearing caps are installed in their original positions. Torque the bearing cap bolts to the figure given in the Data Section.
15. Install the thrust bearing cap and check crankshaft end play by following steps 13 — 20 under “Crankshaft Installation”.
16. Turn the engine on the work stand so that the front end is up.
17. Install the pistons and connecting rods by following procedure under “ Piston and Connecting Rod Installation.”
18. Position the sprockets and timing chain on the camshaft and crankshaft (Fig. 61). Be sure the timing marks on the sprockets are positioned as shown in Fig. 60.
19. Lubricate the timing chain and sprockets with engine oil.
20. Install the fuel pump eccentric, washer and cam-shaft sprocket cap screw. Torque the sprocket cap screw to 30-35 lbs. ft. Install the crankshaft front oil slinger (Fig. 63).
21. Clean the cylinder front cover and the cylinder block gasket surfaces. Install a new crankshaft front oil seal (Fig. 62).
22. Coat the gasket surface of the block and cover and the cover bolt threads with sealer. Position a new gasket on the block.
23. Install the alignment pilot tool on the cylinder front cover so that the keyway in the pilot aligns with the key in the crankshaft. Position the cover (and water pump) and pilot over the end of the crankshaft and against the block (Fig. 64).
24. Install the cylinder front cover screws finger-tight (one screw retains the fuel line bracket). While pushing it on the pilot, tighten the cover bolts. Remove the pilot.
25. Lubricate the crankshaft with a white lead and oil mixture and lubricate the oil seal rubbing surface with grease.
26. Line up the crankshaft vibration damper keyway with the key on the crankshaft, then install the vibration damper on the crankshaft (Fig. 65). Install the damper cap screw and washer, and torque the screw to 70—90 lbs. ft.
27. Install the crankshaft pulley.
28. Turn the engine on the work stand so that the top of the engine is up.
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29. Clean the cylinder head and block gasket surfaces. Install the head gasket over the cylinder head dowels.
30. Place the cylinder head on the engine, then remove the holding fixtures. Coat the head bolt threads with water-resistant sealer, and then install the bolts.
31. The cylinder head bolt tightening procedure is performed in three progressive steps. Torque the bolts in sequence (Fig. 48) to 50 ft./lbs., then to 60 ft./lbs., and finally to 70 ft./lbs. After the cylinder head bolts have been torqued to the figure given in the Data Section, the bolts should not be disturbed.
32. Coat the mating surfaces of the exhaust manifold with a light film of graphite grease. Position new gaskets on the muffler inlet pipe.
33. Position the exhaust manifolds on the cylinder heads and install the retaining bolts and tab washers. Torque the retaining bolts to the figure given in the Data Section, working from the centre to the ends. Lock the bolts by bending one tab of the washer over a flat on the bolt.
34. Install the spark plugs.
35. Coat the outside of each valve lifter with engine oil to provide Initial lubrication. Do not fill the lifters with oil. The lifters will fill much faster after the engine is started, if they are free of any oil film which may cause an oil seal between the plunger and the lifter body. Place each lifter in the bore from which it was removed.
36. Install the push rods in their original positions. Apply Lubriplate over the valve stem tips and the push rod guides in the cylinder head. Install the rocker arms over the push rods. Perform a valve clearance adjustment as outlined under “Adjust-ments”, page 21.
37. Clean the mating surfaces of the intake manifold, cylinder heads and cylinder block.
38. Coat the intake manifold and cylinder block seal surfaces with oil-resistant sealer.
39. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets Interlocked with the seal tabs. Be sure the holes in the gaskets are aligned with the holes in the cylinder heads. The correct installation of the gaskets and seals is shown in Fig. 53.
40. Carefully lower the intake manifold on the cylinder block and cylinder heads. After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.
41. Be sure the holes in the manifold gaskets and manifold are in alignment. Position the Intake
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