Engine Reassembly: Notes
- Oil all rotating or sliding parts. Replace all gaskets with new ones. Grease oil seal lip before installation. Use sealing compound where required. Recheck all running clearances.
- Install connecting rods on crankshaft. Position connecting rod name mark and rod cap projecting side of rib facing forward. Torque rod nuts to specifications.
- Install rings on piston as shown in illustration. Install circlip in side of piston with top mark.
- Using a ring compressor install piston in bottom of cylinder liner leaving piston pin bore outside of liner. Match top mark on piston with mark on cylinder liner flange.
- Insert Woodruff key in camshaft keyway. Install camshaft plate with protrusion side facing away from bearing journal. Press on camshaft gear with 1.575" boss facing toward bearing journal.
- Install valves and springs in both heads with wide spaced coils (yellow paint end) facing toward spring retainers. Use care not to damage lip of intake oil seal or "O" rings. "O" ring fits into groove in spring retainer. Tap valves with a plastic mallet to seat valves.
- Screw drain plugs into heads. Rocker shaft spacers are marked "R" and "L", use care to see that they are installed on proper head. Assemble rocker shaft assemblies and set aside for later installation.
- Place main bearing halves in each side of crankcase. Install lifters in crankcase using lifter clips to prevent them from falling out.
- Lay crankshaft and camshaft into crankcase, aligning timing marks. Fit crankcase halves together and install and torque nuts or bolts to specifications. Install crankcase hangers at this time.
- Position camshaft plate to crankcase. Install bolts and locks through hole in camshaft gear. Torque bolts to specifications and bend up lock tabs. Place engine on suitable engine stand.
- Rotate No. 3 cylinder to TDC. Position No. 3 piston, liner and liner gasket so that piston and circlip may be installed with piston facing correct direction.
- Repeat operation for No. 1 piston. Install a spacer (899838600) and nut over a cylinder head stud on both cylinders to prevent liners from moving out of cylinder block.
- Rotate engine so No. 2 and No. 4 liners may be installed and repeat installation operation. Check all cylinder liners projection above block. Adjust by selecting proper cylinder gasket if necessary.NOTE: Cylinder projection above block must be correct to achieve a proper seal when cylinder heads are installed.
- Apply sealing compound to both sides of head gasket. Install gasket and cylinder head using a suitable aligning tool (899723100 for EA61 and 899738600 for EA62 & 63). Tighten cylinder head nuts gradually in proper sequence (see Fig 2).NOTE: Spacers will be required on rocker shaft studs.
Remove spacers and nuts after cylinder head has been tightened.
- Install push rods in their proper locations. Loosen tappet adjusting screws and install rocker arm assemblies torquing bolts to specifications.
- Install crankcase plug and gasket. Assemble water pipe elbow, pipe and hose with clamps and attach to water pump. Using four steps torque bolts to specifications.
- Install oil pump and filter to crankcase and torque bolts to specifications. Apply sealing compound to oil pressure switch and install. Install intake manifold assembly and carburetor. Tighten all bolts evenly in three steps to specifications.
- Install engine breather pipe and dipstick. Drive rear main bearing oil seal into crankcase. Use care not to damage oil seal. Coat flywheel housing contact surfaces with sealing compound and install, torquing attaching bolts to specifications.
- Coat attaching bolts with sealing compound and attach flywheel assembly and lock washers. Using a suitable tool (899064110), drive front main bearing oil seal into crankcase.
- Slide crankshaft pulley onto crankshaft and torque attaching bolt and washer to specifications.NOTE: Insert a rod through hole in flywheel to prevent turning during tightening.
- Adjust valve clearance and install valve cover and gasket. Set No. 1 piston to TDC, align distributor gear and distributor housing mark. Set arrow mark of indicator to zero position of octane selector. Insert distributor and "O" ring into crankcase and adjust timing.
- Install spark plugs and generator bracket. Install generator assembly and air cleaner bracket. Install drive belt. Reverse removal procedure for remaining components.
VALVES
| Engine & Valve | Head Diam. In. (mm) | Face Angle | Seat Angle | Seat Width In. (mm) | Stem Diameter In. (mm) | Stem Clearance In. (mm) | Valve Lift In. (mm) | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| EA61 | ||||||||||||
| Int. | 1.246-1.256 (31.65-31.90) | 45° | 45° | .... | .3134-.3140 (7.96-7.98) | .001-.0022 (.025-.055) | .... | |||||
| Exh. | 1.083-1.091 (27.51-27.71) | 45° | 45° | .... | .3125-.3134 (7.94-7.96) | .0016-.003 (.040-.077) | .... | |||||
| EA62 & 62S | ||||||||||||
| Int. | 1.452-1.461 (36.88-37.11) | 45° | 45° | .... | .3134-.3140 (7.96-7.98) | .001-.0022 (.025-.055) | .... | |||||
| Exh. | 1.280-1.288 (32.51-32.72) | 45° | 45° | .... | .3128.3134 (7.94-7.96) | .0016-.0028 (.040-.077) | .... | |||||
| EA63 & 63S | ||||||||||||
| Int. | 1.452-1.461 (36.88-37.11) | 45° | 45° | .043 (1.1) | .3134-.3140 (1) (7.96-7.98) (1) | .001-.0022 (2) (.025-.055) (2) | .... | |||||
| Exh. | 1.280-1.288 (32.51-32.72) | 45° | 45° | .063 (1.6) | .3124-.3130 (7.93-7.95) | .002-.0032 (.05-.08) | ..... | |||||
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