853869T Force STARTER ASSEMBLY

Illustration 1 g00584368 (1) Cylinder head studs Use the following procedure in order to install the cylinder head studs:
Coat the lower half of each stud with 1.5 mm (0.06 inch) thick coating of 4C-4774 Water and Temperature Resistant Grease.
Thoroughly clean the top of the cylinder block.
Install the cylinder head studs. Torque ... 100 20 N m (75 15 lb ft)
Apply a bead of grease at the top of the block around each stud. This will ensure that the counterbore is filled with grease.
Coat the upper half of each stud with 1.5 mm (0.06 inch) thick coating of 4C-4774 Water and Temperature Resistant Grease. Apply 8T-9014 Silicone Sealant to covers (2) when the covers are installed onto the block. (3) Protrusion of the dowels from the rear face of the cylinder block ... 20.0 1.0 mm (0.79 0.04 inch) (4) Protrusion of the dowels from the front face of the cylinder block 6V-3540 Dowel ... 55.0 1.0 mm (2.17 0.04 inch) 7N-2328 Dowel ... 20.0 1.0 mm (0.79 0.04 inch)
Illustration 2 g00480025
Front view of cylinder block
(5 and 6) Dimension for dowels Apply 4C-4774 Water and Temperature Resistant Grease to the dowel before the cylinder head is installed. Protrusion of the dowels above the upper portion of the deck for the cylinder head ... 60.0 1.0 mm (2.36 0.04 inch)Protrusion of the dowels above the lower portion of the deck for the cylinder head ... 8.0 1.0 mm (0.32 0.04 inch) (7) Nut for the main bearing cap Use the following procedure for tightening the main bearing caps.
Before assembly of the main bearing cap, lubricate the studs with engine oil.
Assemble the main bearing cap and the washer. Hand tighten the nut.
Tighten all side bolts hand tight on the side of the tab slot of the cap. Torque ... 215 40 N m (159 30 lb ft)
Simultaneously tension each pair of the studs with either of the following tensioners: 207-5034 Stud Tensioner Tool Gp ... 65000 2400 kPa (9425 350 psi) 191-5320 Stud Tensioner Tool Gp ... 111500 3950 kPa (16200 575 psi)
Tighten nuts by hand and then release the tension.
Repeat Step 4.
Tighten all side bolts hand tight on the opposite side of the tab on the cap. Torque ... 215 40 N m (159 30 lb ft)
Lubricate the washers and the threads of the side bolts (9) and tighten the bolts. Torque ... 1825 175 N m (1340 130 lb ft) (8) Bore and main bearing Bore in the block for main bearings ... 265.000 0.020 mm (10.4330 0.0008 inch) 1.00 mm (.040 inch) oversize bearing ... 266.000 0.020 mm (10.4724 0.0008 inch) 2.00 mm (0.080 inch) oversize bearing ... 267.000 0.020 mm (10.5118 0.0008 inch)
Illustration 3 g00584867
Rear view of cylinder block
(10) Protrusion of the dowels above the cylinder block face ... 8.0 1.0 mm (0.32 0.04 inch) (11) Dimensions for main bearing cap and block Width of main bearing cap ... 499.95 0.03 mm (19.683 0.001 inch)Width of cylinder block for main bearing cap ... 500.00 0.05 mm (19.685 0.002 inch)Clearance between the sides of the main bearing cap and the cylinder block ... 0.03 to 0.13 mm (0.001 to 0.005 inch)
Illustration 4 g00584890
(12) Dimension for dowel
(13) Main bearing cap (12) Protrusion of the dowel from the main bearing cap ... 10.0 0.5 mm (0.39 0.02 inch)