Assembly
GENERAL INSTRUCTIONSLubricate all internal parts with engine oil during reassembly.
NOTE:
- Apply liquid gasket to the mating surfaces of the rear cover and oil pump case before installing them.
- Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003.
NOTE:
- Lubricate all internal parts with engine oil during reassembly.
- Use liquid gasket, Part No08718 - 0001 or 08718 - 0003.
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft identification markings.
Lubricate all internal parts with engine oil during reassembly.
PISTONS
OIL: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
1. If the crankshaft already installed:
- Guide the piston carefully to prevent damage.
- Fit long rubber hoses (about 30 cm (12 inch) long) to the connecting rod bolts to protect the crankshaft.
- Install the pistons after setting the crankshaft to BDC for each cylinder.
- Remove the connecting rod caps, then slip the long rubber hoses over the threaded ends of the connecting rod bolts.
- 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.
- Stop aver the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
- Install the rod caps with bearings, and torque the nuts to 44 Nm (33 ft. lbs.).
2. If the crankshaft is not installed:
- Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
NOTE: Maintain downward force on the ring compressor to prevent rings from expanding before entering the cylinder bore.
CRANKSHAFT
OIL: Before installing the crankshaft, apply a coat of all engine oil to the main bearings and rod bearings.
1. Insert the bearing halves in the cylinder block and connecting rods.
2. Lower the crankshaft into the block.
3. Install the thrust washers on the No. 4 journal. Oil the thrust washer surfaces.
4. Install the bearings and caps. Torque the cap bolts.
5. Check the connecting rod bearing clearance with plastigage, then torque the connecting rod cap nuts.
NOTE: Reference numbers on the connecting rods are for big-end bore tolerance and do NOT indicate the position of the piston in the engine.
6. Tighten the 9 x 1.25 mm cap bolts to the specified torque.
Torque: 39 Nm (29 ft. lbs.)
7. Tighten the 11 x 1.5 mm cap bolts to the specified torque.
Torque: 76 Nm (56 ft. lbs.)
Bearing Cap Bolts Torque Sequence:
8. Tighten the 10 x 1.25 mm cap side bolts to the specified torque.
Torque: 49 Nm (36 ft. lbs.)
- Coat the bolt thread and seat surfaces with engine oil.
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.
9. Apply liquid gasket to the cylinder block mating surface of the rear cover, then install it 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 aver 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 and to the lip of the oil seal.
- Use a new O-ring and apply oil when installing it.
- Use new special bolts when installing the rear cover.
10. Apply liquid gasket to the cylinder block mating surface of the oil pump.
NOTE: Do not apply liquid gasket to 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.
- Use new special bolts when installing the oil pump housing.
11. Install the oil pump with new O-rings.
12. Apply liquid gasket to the cylinder block, then install the oil pan.
NOTE:
- Do not apply liquid gasket to the O-ring grooves.
- Use new O-rings and apply oil when installing them.
Oil Pan Bolt Tightening Sequence:
13. Tighten the oil pan bolts as shown.
Torque: 8 x 1.25 mm: 22 Nm (16 ft. lbs.)