0320939 JOHNSON COVER,Bypass,lower port

Illustration 1 g00366556
(1) Tighten the three studs that hold the water pump to the following torque. ... 35 5 N m (25.8 3.7 lb ft) (2) There are two plugs on the front of the cylinder block. There are two plugs on the rear of the cylinder block. Put 5P-3413 Pipe Sealant on the threads of the plugs before assembly. (3) The dowels extend from the cylinder block. Distance ... 18.5 0.5 mm (0.73 0.02 inch) (4) The gasket that is between the cylinder block and the top plates is the following thickness. ... 0.208 0.025 mm (.0082 .0010 inch) (5) Thickness of the top plates ... 8.585 0.025 mm (.3380 .0010 inch) (6) Refer to Systems Operation / Testing and Adjusting, "Cylinder Liner Projection" for the cylinder liner projection. (7) The camshaft bearing bore is the following value. ... 76.835 0.018 mm (3.0250 .0007 inch) (8) Put 5P-3413 Pipe Sealant on the threads of the plugs before assembly. Tighten the plug that is in the front of the block and tighten the plug that is in the rear of the block to the following torque. ... 80 15 N m (60 10 lb ft) (9) Bore in cylinder block for main bearings New bearings that are standard size ... 129.891 0.013 mm (5.1138 0.0005 inch) Bearings that are 0.64 mm (.025 inch) larger than the standard size ... 130.526 0.013 mm (5.1388 0.0005 inch) (10) There are two dowels that are in the front of the cylinder block. There are two dowels that are in the rear of the cylinder block. The dowels project from the cylinder block. Distance ... 19.0 0.5 mm (.75 .02 inch) (11) The width of the slot for the main bearing caps is the following value. ... 215.900 0.013 mm (8.5000 .0005 inch)Width of main bearing cap ... 215.900 .025 mm (8.5000 0.0010 inch) (12) Tighten the bolts that hold the piston cooling jets to the following torque. ... 25 7 N m (18.5 5 lb ft) (13) Use the procedure that follows to install the main bearing caps.
Install the main bearing caps with the arrows toward the front of the engine. Each main bearing cap is numbered on the bottom. Main bearing caps must be installed in the same position as the main bearing caps were originally installed. A corresponding number is on the left side of the cylinder block pan rail.
Lubricate the threads of the main bearing cap bolts with engine oil.
Tighten the bolt on the tab end.Torque for bolts ... 258 14 N m (190 10 lb ft)
Tighten the bolt that is opposite the tab end.Torque for bolts ... 258 14 N m (190 10 lb ft)
Place a mark on each cap and each bolt.
Additionally tighten the bolt that is opposite the tab end.Distance ... 120 5 degrees
Additionally tighten the bolt on the tab end.Distance ... 120 5 degrees
Illustration 2 g00366557
(14) The distance from the centerline of the crankshaft bearing bore to the top of the cylinder block is the following value. ... 419.10 0.15 mm (16.500 .006 inch) (15) The distance from the centerline of the crankshaft bearing bore to the bottom of the cylinder block is the following value. ... 165.10 0.10 mm (6.500 .004 inch)
Illustration 3 g00366558
(16) Two plugs are located on the top right side of the cylinder block. One plug is in the front and one plug is in the rear. Use 4C-9500 Quick Cure Primer and 4C-9507 Retaining Compound in the plug bores before assembly. (17) Plug. Use 4C-9500 Quick Cure Primer and 4C-9507 Retaining Compound in the plug bore before assembly. (18) Tighten the studs to the following torque. ... 35 5 N m (26 4 lb ft)