Assembly
PISTONSOIL: Before installing the pistons, apply a coat of engine oil to the connecting rod bearings, ring grooves and cylinder bores.
1. Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
NOTE:
- Set the crankshaft to BDC for each cylinder.
- Position the arrow mark on the piston top on the timing belt side of the engine.
NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
2. Stop after the ring compressor pops free and check the connecting rod-to-crank journal alignment before pushing the piston into place.
3. Check the connecting rod bearing clearance with plastigage.
4. Install the rod caps with bearings, and torque the bolts to 20 Nm (14 ft. lbs.).
NOTE: Apply engine oil to the bolt threads.
5. Mark the connecting rod and bolt head as shown.
6. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (Turn the bolt 90 degrees).
CRANKSHAFT
OIL: Before installing the crankshaft, apply a coat of 1# engine oil to the main bearings and rod bearings.
1. Insert the bearing halves into the cylinder block and connecting rods.
2. Lower the crankshaft into the block.
3. Install the thrust washers on the No. 3 journal. Oil the thrust washer surfaces.
4. Install the bearings and bearing caps.
NOTE: The arrow marks on the bearing caps point to the timing belt side of the engine.
5. Check main bearing clearances with plastigage.
6. Install the piston/connecting rod assemblies.
7. Check the connecting rod bearing clearances with plastigage.
8. Install rod caps with bearings, and torque the bolts to 20 Nm (14 ft. lbs.).
NOTE:
- Apply engine oil to the bolt threads.
- Reference numbers on the connecting rods are for big-end bore tolerance and do NOT indicate the position of the piston in the engine.
9. Mark the connecting rod and bolt head as shown.
10. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (Turn the bolt 90 degrees).
11. Tighten the 11 x 1.5 mm cap bolts to the specified torque.
Torque: 76 Nm (56 ft. lbs.)
Apply engine oil to the bolt threads and flange.
12. Tighten the 10 x 1.25 mm cap bolts to the specified torque.
Torque: 49 Nm (36 ft. lbs.)
Apply engine oil to the bolt threads and flange.
CAUTION: Whenever any crankshaft bearing or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for approximately 15 minutes.
13. Apply liquid gasket to the cylinder block mating surface of the left side cover, then install the cover on the cylinder block.
NOTE:
- Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- Apply liquid gasket evenly, being careful to cover all the mating surface.
- To prevent oil leakage, apply liquid gasket to the inner threads of the bolt holes.
- Do not apply liquid gasket to O-ring grooves.
- Do not install the parts if five minutes or more have elapsed since applying liquid gasket. Instead reapply liquid gasket after removing old residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
NOTE:
- Apply a light coat of oil to the crankshaft to the lip of the oil seal.
- Use a new O-ring and apply oil when installing it.
14. Apply liquid gasket to the cylinder block mating surface of the oil pump.
NOTE: Do not apply liquid gasket to the O-ring grooves.
NOTE:
- Apply a light coat of oil to the crankshaft and to the lip of the seal.
- Use new O-rings and apply oil when installing them.
15. Install the oil pump baffle plate and oil screen.
16. Apply liquid gasket to the cylinder block, then install the oil pan.
17. Tighten the oil pan bolts as shown.
OIL SEAL
NOTE:
- Engine removal is not required. The crankshaft oil seal housing should be dry.
- Apply a light coat of grease to the crankshaft and to the lips of the seals.
1. Using the special tool, drive in the timing pulley-end seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.
2. Measure the flywheel-end seal thickness and the oil seal housing depth. Using the special tool, drive the flywheel-end seal into the left side cover until the driver bottoms against the cover.