809735A 1 Force REPAIR KIT, Carburetor

Illustration 1 g00503937
View from the front of the cylinder block (1) Spacer plate and gasket thickness Thickness of the spacer plate ... 8.585 0.025 mm (.3380 .0010 inch) The thickness of the gasket that is placed between the spacer plate and the engine block ... 0.208 0.025 mm (.0082 .0010 inch) The height of the cylinder liner above the spacer plate is the following dimension. ... 0.0885 0.0635 mm (.0035 .0025 inch)Note: The height of the cylinder liner above the spacer plate is measured under the pressure of installation. (2) Dimension from the centerline of the crankshaft bearing bore to the top of the block (top deck) New ... 425.45 0.15 mm (16.750 .006 inch) Minimum ... 425.02 mm (16.733 inch)Note: The flatness across the entire contact surface of the block must be within 0.10 mm (.004 inch). The flatness across any 177.5 mm (6.99 inch) section of the surface must be within 0.05 mm (.002 inch). The specification for the maximum surface finish which is allowed is 0.0032 mm (.0001 inch). (3) Bolt Tighten the four bolts to the following torque. ... 25 6 N m (18 4 lb ft) (4) Plug Tighten the plug to the following torque. ... 70 10 N m (52 7 lb ft) (5) Bore in the block for the main bearings Standard size for new bearings ... 129.891 0.013 mm (5.1138 .0005 inch) 0.64 mm (.025 inch) larger than original size ... 130.526 0.013 mm (5.1388 .0005 inch) (6) Bore in the block for the camshaft bearings Bore ... 76.835 0.018 mm (3.0250 .0007 inch)Note: Install the camshaft bearings with the oil holes in the bearings on the horizontal centerline. Make sure that the position of the bearing joint is above the oil holes. (7) Plug Tighten the plug to the following torque. ... 35 7 N m (26 5 lb ft) (8) Dimensions for main bearing cap Width of the main bearing cap ... 215.900 0.025 mm (8.5000 .0010 inch) Width of the block for the main bearing cap ... 215.900 0.025 mm (8.5000 .0010 inch) Clearance between the sides of the main bearing cap and the cylinder block ... 0.038 mm (.0015 inch) tight fit to 0.038 mm (.0015 inch) loose fit (9) Plug Tighten the plug to the following torque. ... 70 10 N m (52 7 lb ft) (10) Main bearing cap boltsNote: Install the main bearing caps in order to orient the arrows that are stamped on the main bearing caps toward the front of the engine. Install each cap in the correct position. The number which is stamped on the bottom side of each cap should be placed toward the corresponding number which is cast on the cylinder block.The following steps describe the correct installation of the main bearing cap bolts. (a) Apply 4C-5593 Anti-Seize Compound to the following components. ... Main bearing cap bolts (b) Tighten the bolts on the bearing tab side of the bearing cap first to the following torque. ... 258 14 N m (190 10 lb ft) (c) Tighten the bolts on the opposite side of the bearing tab to the following torque. ... 258 14 N m (190 10 lb ft) (d) Turn the bolts on the opposite side of the bearing tab side clockwise through the following angle. ... 120 5 degrees (e) Turn the bolts on the side of the bearing tab side clockwise through the following angle. ... 120 5 degrees (11) The distance from the centerline of the crankshaft bearing bore to the bottom of the cylinder block is the following dimension. ... 165.10 0.10 mm (6.500 .004 inch)
Illustration 2 g00503939
View from the right hand side of the cylinder block (12) Height of the two end dowels above the surface of the cylinder block ... 18.5 0.5 mm (.73 .02 inch)Note: Put 7M-7456 Bearing Mount Compound on the two end dowels before installation in the cylinder block. (13) Height of the two middle dowels above the surface of the cylinder block ... 16.0 0.5 mm (.63 .02 inch) (14) Distance of protrusion of the dowels from the face of the cylinder block ... 19.1 0.5 mm (.75 .02 inch) (15) Piston cooling jet Tighten the bolts that hold the piston cooling jets to the following torque. ... 35 3 N m (26 2 lb ft) Minimum permissible clearance between the piston and the piston cooling jet ... .64 mm (.025 inch)
Illustration 3 g00503548
View from the front of the cylinder block (16) Dimension from vertical centerline of the dowel hole to the vertical centerline of the pilot bore ... 186.33 mm (7.336 inch) (17) Idler gear shaft pilot bore Idler gear shaft pilot bore in the cylinder block ... 31.750 0.025 mm (1.2500 .0010 inch) Depth of the bore from the surface of the cylinder block ... 11.9 2.5 mm (.47 .10 inch) (18) Distance from the horizontal centerline of the dowel and the crankshaft to the horizontal centerline of the pilot bore ... 247.02 mm (9.725 inch)