CRANKSHAFT BEARING CAPS Examine   crankshaft   front   and   rear   bearing   caps   and replace if cracked.  Check seal diameter of rear cap.  If diameter is not within dimension listed in SPECIFICATIONS in this Section, the rear cap must be replaced. Only  compressors  which  have  ball  rear  main  bearings and  are  oiled  through  the  rear  of  the  crankshaft  have  a seal  and  spring  or  bowed  washer.    If  bowed  washer  or spring is worn, it must be replaced. CRANKCASE Inspect    crankcase    for    damage    and    replace    if    any damage   is   noted.      Also   inspect   studs   (if   used)   and replace any that are bent or damaged. SEALS AND GASKETS Replace    all    seals    and    gaskets.        Never    re-use    any gaskets or seals. ASSEMBLY Apply   a   coat   of   engine   oil   to    crankshaft,    bearings, connecting rod bearings, pistons and cylinder block bore. CRANKSHAFT AND BEARINGS 1. Position     the     crankcase     in     an     arbor     press supporting  the  crankcase  on  the  rear  end  cap surface.          Install     the     front     bearing     in     the crankcase.  Press the bearing into the crankcase so it extends outside the crankcase about .3929 cms (.135 in.) (Figure 8).  Do not apply pressure to the inner race only. 2. Position  the  crankcase/bearing  assembly  in  the arbor   press   supporting   the   assembly   on   the inner race of the  bearing.    Install  the  crankshaft into  the  bearing.    Press  the  crankshaft  into  the bearing    applying    force    to    the    rear    of    the crankshaft  until  the  inner  race  of  the  bearing  is seated     firmly     against     the     shoulder     of     the crankshaft.  Care must be taken not to damage the    oil    sealing    surface    on    the    rear    of    the crankshaft. 3. With the assembly still in the arbor press, place the  rear  bearing  on  the  crankshaft.    Press  the bearing     onto     the     crankshaft     and     into     the crankcase  applying  force  to  both  the  inner  and outer  race  of  the  bearing  until  the  inner  race  is seated     firmly     against     the     shoulder     of     the crankshaft. CRANKSHAFT BEARING CAPS 1. Apply  a  thin  coat  of  Loctite  Gasket  Eliminator (purple) around the perimeter of the front bearing cap oil seal.  The coating must be light yet cover the seal fit area. 2. Press  a  new  seal  into  front  bearing  cap.    Lip  of seal   must   face   towards   the   crankcase   when installed. The  seal  case  must  be  flush  to  .0127  cm  (.005 in.) below the front of the cap. 3. Position  a  new  gasket  over  crankshaft  between crankcase and bearing cap. 4. Position   bearing   cap   over   end   of   crankshaft taking care not to damage oil seal. 5. Pull     bearing     cap     into     place     by     alternately tightening    the    four    bolts.        Tighten    bolts    to specified  torque  listed  in  TORQUE   CHART   in this Section. 6. Position   new   gasket   over   crankshaft   between crankcase and rear bearing cap. 7. Place bowed washer or spring in bearing cap so that   the   outside   diameter   of   washer   contacts bottom of hole in bearing cap.  Place seal in rear of end cap and lubricate with engine oil. 8. Slide  rear  bearing  cap  over  rear  of  ball  bearing taking   care   that   bowed   washer   or   spring   and seal do not fall out of cap. 9. Pull     bearing     cap     into     place     by     alternately tightening    the    four    bolts.        Torque    bolts    to specified  torque  listed  in  TORQUE   CHART   in this Section. CYLINDER BLOCK Place   a   new   cylinder   block   to   crankcase   gasket   on crankcase;  then  position  the  cylinder  block  on  gasket. Install  six  bolts  and  lock  washers.    Tighten  two  center bolts  to  10.847  N-m  (8  Ib-ft)  prior  to  tightening  the  four end   bolts.      Increase   bolt   torque   to   specified   torque, tightening center bolts first, then the four end bolts. PISTONS AND CONNECTING RODS 1. Position   connecting   rod   in   piston;   then   press piston pin in place.  Install snap rings in piston at both ends of piston pin (Figure 7). 2. Install two compression rings in each of the two grooves and two oil rails and expander in bottom groove (Figure 7). Compression     rings     must     be     installed with surface    marked    "TOP"    facing    top    of    piston. Some    compression    rings    may    have    dots    to indicate top of ring. 3. Position   connecting   rod   bearing   inserts   in   rod and  bearing  cap,  making  sure  that  the  locating lips on inserts engage the locking notches in rod and  cap.    Insure  that  arrows  on  caps  and  rod match as shown in Figure 12.  Also, make sure that the rod cap is installed on rod from which it was removed. 4. Remove  connecting  rod  bearing  cap  with  insert from  rod  assembly.    Stagger  ring  gaps  in  each ring  groove  by  about  180  degrees.    Use  a  ring compressor  and  insert  piston  so  that  the  top  of the piston is flush with top of block. CTS-4077Y Page 10