0320835 JOHNSON LEVER,Throttle

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     2P-5518     Bearing Tool     1    
B     -     Plastigage     -    
C     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 without lubricant when the check for the crankshaft main bearing clearance is made. Put clean engine oil on the crankshaft main bearings for final assembly.
Illustration 1 g00503404
Note: Ensure that the main bearings are installed so that bearing tabs (3) fit into the notch in the cylinder block and in the main bearing caps.
Install new crankshaft main bearings in the main bearing caps.
Illustration 2 g00503174
Install the upper halves of the main bearings in the cylinder block with Tool (A) .
Illustration 3 g00566702
The engine is inverted on 4C-9832 Engine Rollover Stand .Note: When the bearing clearance is checked and the engine is in an upright position or on a side position, the crankshaft must be supported against the upper halves of the main bearings. This is done in order to get a correct measurement with Tool (B). If the crankshaft is not supported, the weight of the crankshaft will cause an incorrect reading. If the engine is inverted it is not necessary to hold the crankshaft upward. Do not rotate the crankshaft when Tool (B) is installed.Note: Refer to Special Publication, SEBD0531, "Engine Bearings and Crankshafts" for complete details concerning measuring of bearing clearances.
Check the bearing clearances with Tool (B). Put Tool (B) on the bearing surfaces.
Illustration 4 g00503665
Illustration 5 g00503673
Note: Ensure that the numbers on the main bearing caps match the numbers on the cylinder block. The arrows (4) on the main bearing caps are toward the front of the cylinder block.Note: Install the thrust plates with the identification "Block Side" toward the cylinder block.
Install the main bearing caps for No. 2 through No. 6 main bearings. Put clean engine oil on the bolts. Install the bolts in the main bearing caps. Tighten the bolt on the tab end of the main bearing cap. Next, tighten the other main bearing cap bolt. Tighten all bolts to a torque of 258 14 N m (190 10 lb ft). Put a mark on each bolt and each main bearing cap. Tighten the bolt opposite the tab end of the main bearing cap 120 5 degrees further. Next, tighten the bolt on the tab end of the main bearing cap 120 5 degrees further.
Remove the main bearing caps for No. 2 through No. 6 main bearings. Measure the thickness of Tool (B). Remove Tool (B) from the main bearing caps. This measurement is the main bearing clearance. The bearing clearance must be 0.091 to 0.186 mm (0.0036 to 0.0073 inch) with new main bearings. Maximum clearance with used main bearings is 0.25 mm (0.010 inch).
Put clean engine oil on the bolts and threads. Install the bolts in the main bearing caps. Tighten the bolt on the tab end of the main bearing cap. Next, tighten the other main bearing cap bolt. Tighten all bolts to a torque of 258 14 N m (190 10 lb ft). Put a mark on each bolt and each main bearing cap. Tighten the bolt opposite the tab end of the main bearing cap 120 5 degrees further. Next, tighten the bolt on the tab end of the main bearing cap 120 5 degrees further.
Remove the No. 1 and No. 7 main bearing caps. Refer to Disassembly and Assembly, "Cranskshaft Main Bearings - Remove". Repeat Steps 1 through 6 for the No. 1 and No. 7 main bearing caps.
Illustration 6 g00504380
Note: Install the thrust plates with the identification "Block Side" toward the cylinder block.
Check the end play of the crankshaft with Tool (C). Ensure that Tool (C) is against a machined surface. The end play is controlled by the thrust plates of No. 4 main bearing (center). The end play with new thrust plates must be 0.13 to 0.50 mm (0.005 to 0.020 inch). The maximum permissible end play with used thrust plates is 0.89 mm (0.035 inch).End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".