Assembly Procedure:

1st stage: (sheet 2/5)

 Cap assembly
 Crankshaft gear assembly
 Crankshaft fitment torquing
 Clean the crankshaft bore in all the bearing caps and crankcase
 Insert grooved engine bearing
 Clean journals and pipes of crankshaft to remove any dirt
 Hand tight bearing caps on crankshaft
 Checking free rotation of crankshaft

2nd sub assembly: sheet(1,2,3/3)

 Camgear heating
 Woodruff key fitment
 Thrust plate inserting
 Cam gear pressing
 Circlip fitment
 Oil ring inserting on piston
 Inserting piston pin
 Connecting rod fitment
 Water connection rod pressing
 Copper shim location
 Oil ring inserting and linear pressing
 Joint placing
 Piston connecting rod assembly inserting in cylinder block
 Engine bearing fixing
 Assembly of cap on connecting rod
2nd A stage : (sheet 1-7/7)
 Crankcase mounting on engine assembly trolley conveyor
 Camshaft assembly fitment
 Intermediate gear support fitment
 Intermediate gear fitment
 Retaining plate tightening
 Crankgear outer fitment
 Deflector mounting
 Setting bush fitment
 Tappet bore lubrication
 Valve tappets insertion
 Cylindrical head stud tightening
 Gasket placing on studs
 Dowel fitmenet on gear casing
 Gasket sticking
 FIP stud tightening
 Relief valve fitment
 Torquing relief valve plug
 Gear casing fitment
 Gear casing tightening
 Removing protection cap
 Lubrication oil filter tightening
 FAB stud tightening
 Gear end foot mounting
 Oil seal flaring
 Oil seal pressing
 Crank pulley mounting and tightening
 Dismantling of connecting rod caps
 Cylinder block assembly fitment in linear bore
  Connecting rod tightening and torquing
 Engine rotation checking
 Sealing ring inserting
 Cylinder block assembly fitment and tightening
 Unscrewing caps of connecting rods
 Piston rings open gap settings
 Piston sub assembly insertion in linear bore
 Connecting rod tightening
 Rotation checking

3rd A stage: (sheet1-8/8)

 Line hydraulic sub assembly
 Bearing pressure
 Gear pressing in spout
 Circlip fitment
 Cover tightening
 Stud tightening
 Exhaust manifold positioning/tightening
 Trolley indexing
 Cycle selection
 Machine alligning
 Mounting plate clamping
 Spindles alligning on cylinder head
 Cycle operation
 Water outlet manifold sub assembly
 Cylinder head tightening/torquing
 Water outlet manifold tightening
 Air inlet manifold tightening
 Trolley indexing
 Engine number punching
 Water seperator mounting
 Fuel filter mounting/tightening
 Joint placing
 T.D.C checking
 B.T.D.C checking
 Rocker sub assembly tightening
 Alternator mounting bracket
 Water pump mounting
 Air inlet manifold sub assembly and tightening
 Push rod placing
 Brass nut
 Alternator mounting bracket tightening
 Water pump mounting
 Air inlet manifold sub assembly & tightening
 FIP mounting
 Push rod placing
 Air inlet manifold/water pump/water inlet manifold/alternator mounting
 FIP tightening
 Adaptor flange tightening
 FIP overflow pipe fitment