Assembly
PISTON INSTALLATIONBefore installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
1. If the crankshaft is 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.
- Install the piston assemblies in No. 1 and No. 4 cylinders, No. 2 and No. 5 cylinders, and No. 3 and No. 6 cylinders.
- 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 after the ring compressor pops free and check the connecting rod-to-crank journal alignment before putting rod into place.
- Install the rod caps with bearings, and torque the nuts to 20 Nm (14 ft. lbs.), then turn the nut 116 degrees.
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 INSTALLATION
Before installing the crankshaft, apply a coat of engine oil to the main bearings and rod bearings.
1. Insert bearing halves in the engine block and connecting rods.
2. Lower the crankshaft into the block.
3. Install the thrust washers on the No. 3 journal. Oil thrust washer surfaces.
4. Install the bearings and caps. Tighten 9 x 1.25 mm cap bolts to the specified torque.
Torque: 39 Nm (29 ft. lbs.)
NOTE:
- Guide the piston carefully to prevent damage.
- Fit long rubber hoses (about 30 cm long) to connecting rod bolts to protect the crankshaft.
- Install the pistons after setting the crankshaft to BDC for each cylinder.
- Line up the marks when installing connecting rod cap.
5. Check the rod bearing clearance with plastigage, then torque the connecting rod cap nuts.
NOTE: Reference numbers on connecting rods are for big-end bore tolerance and do NOT indicate the position of piston in engine.
Connecting Rod Cap Nut Torquing Method
1) Torque the connecting rod cap nut to 20 Nm (14 ft. lbs.) with a beam-type torque wrench.
2) Install a torque angle gauge to the cap nut, then turn the cap nut 116 degrees.
Main Bolt Torque Sequence:
6. Install the bearing cap bridge, and tighten 11 x 1.5 mm bolts to the specified torque diagonally outward from the center.
Torque: 65 Nm (48 ft. lbs.)
7. Tighten cap side bolts (10 x 1.25 mm) to the specified torque.
Torque: 49 Nm (36 ft. lbs.)
- Coat the bolt thread and seat surface with engine oil.
NOTE: The shorter side bolts are for the front side.
8. Apply liquid gasket to the block mating surface of the led side cover and oil pump case, and install them on the engine block.
NOTE: The seal surface on the block should be dry. Apply a light coat of oil to the crankshaft and to the lip of seal.
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 of the mating surface.
- To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
- 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 20 minutes before filling the engine with oil.
9. Install the oil pass pipe and joint.
10. Install the baffle plate.
11. Install the oil screen.
12. Install the oil pan.
CAUTION: Whenever any crankshaft or connecting rod bearing is replaced, after reassembly, run the engine at idling speed until it reaches normal operating temperature, then continue to run for approximately 15 minutes.
OIL SEALS INSTALLATION
The seal surface on the block should be dry. Apply a light coat of oil to the crankshaft and to the lip of the seal.
1. Using the special tools, drive in the flywheel-end seal until the driver bottoms against left side cover.
2. Confirm clearance is equal all the way around with a feeler gauge.