813613 Force FITTING, Telltale (Cut as Req'd 1991C Thru 1992C)

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     -     Plastigage     -    
B     8T-5096     Dial Indicator Group     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.Note: Ensure that the upper halves and the lower halves of the main bearings are installed so that the bearing tabs fit into the bearing tab grooves in the cylinder block and in the main bearing caps.
Ensure that the main bearing surfaces in the cylinder block are clean prior to main bearing installation. Install the upper halves of the main bearings in the block.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Heat the crankshaft gear to a maximum temperature of 315 °C (600 °F). Install the crankshaft gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all of the timing marks in alignment.
Ensure that the main bearing caps are clean prior to bearing installation. Install the lower halves of the main bearings in the main bearing caps.Note: When the bearing clearance is checked and the engine is in an upright position (vertical position), the crankshaft must be lifted upward and the crankshaft must be held against the upper halves of the main bearings. This is done in order to get a correct measurement with Tooling (A) (Plastigage). Tooling (A) (Plastigage) will not hold the weight of the crankshaft. Therefore, a correct indication is not given. If the engine is in a horizontal position, it is not necessary to hold the crankshaft upward. Do not turn the crankshaft in order to check the clearances when Tooling (A) (Plastigage) is in the position.Note: Refer to Guideline For Reusable Parts, SEBV0544, "Engine Bearings and Crankshafts" for complete details concerning the measurement of bearing clearances.
Illustration 1 g00484918
Check the main bearing clearance with Tooling (A) (Plastigage), as follows:
Put a piece of Tooling (A) (Plastigage) on the crankshaft journals, as shown.Note: Ensure that the part number on the main bearing cap is facing toward the front of the engine. Also, ensure that the number on the main bearing cap matches the number on the cylinder block on the left side of each main bearing cap.
Put the main bearing caps in position in the engine. Put 4C-5593 Anti-Seize Compound on the bolt threads and the face of the washers. Install the bolts. Tighten the bolts to torque of 40 4 N m (30 3 lb ft).
Put a mark on each bolt and main bearing cap. Tighten the bolts for an additional 90 degrees.
Remove the main bearing caps and measure Tooling (A) (Plastigage) in order to find the bearing clearance. The main bearing clearance for new bearings must be 0.076 mm (0.0030 inch) to 0.165 mm (0.0065 inch). The maximum permissible clearance with used bearings is 0.25 mm (0.010 inch).
Illustration 2 g00484946
Put clean oil on thrust bearing (1) and install a new thrust bearing for the rear main bearing. Install the thrust bearing so that the mark that is identified at the "BLOCK SIDE" faces toward the cylinder block and toward the tabs on the thrust bearings in the machined area in the cylinder block. The tabs on thrust bearing (1) will not allow the thrust bearing to be installed backward.
Install the main bearing caps. Use the same procedure that is described in Step 4.b and Step 4.c.
Use Tooling (B) in order to check the crankshaft end play. The end play is controlled by the thrust bearings on the rear main bearing. End play with new bearings must be 0.122 (0.0048 mm) to 0.579 (0.0228 inch).End By:
Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
Install the timing gear cover. Refer to Disassembly and Assembly, "Front Housing - Remove".