Assembly

NOTE: Numbers in text correspond to numbered components in images.

1. Cylinder block [14]





2. Crankshaft [13]
^ Install the main bearings to the cylinder block and the main bearing caps. Be sure that they are positioned correctly.
^ Apply new engine oil to the upper and lower main bearing faces.
^ Carefully mount the crankshaft.
^ Apply engine oil to the thrust washer.





^ Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft.





3. Crankshaft bearing cap [12]
^ Apply engine oil to the threads and the seating faces of the bolts.
^ Install bearing caps in the order shown with the No.1 as the front most bearing cap.

Main Bearing Cap Tightening Sequence:

^ Semi-tighten all of bolts. Finally, tighten all the bolts to 39 Nm (29 ft. lbs.) in the order shown.
^ After the final tightening, check to see that the crankshaft rotates smoothly.
4. Rear oil seal assembly [11]
^ Tighten all the bolts to 18 Nm (13 ft. lbs.).





5. Flywheel [10]
a. Thoroughly clean and remove the oil from the threads of crankshaft.
b. Remove the oil from the crankshaft and flywheel mounting faces.
c. Mount the flywheel on the crankshaft and then install the washer.
d. Holding the crankshaft stationary, tighten the flywheel bolts to 54 Nm (40 ft. lbs.) in the order shown.

NOTE:
^ Do not reuse the bolts.
^ Do not apply oil or thread lock to the bolts.





6. Piston and connecting rod assembly [9]
^ Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins.

NOTE:
^ Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces.
^ Check to see that the piston ring end gaps are correctly positioned.
^ Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor.





^ The front marks must be facing the front of the engine.

7. Oil gallery [8]
^ Tighten the bolts in 2 steps in the order shown.
- 1st step tighten to 29 Nm (22 ft. lbs.)
- 2nd step tighten 55-65° more





8. Crankcase side bolts [7]
^ Tighten crankcase bolts in sequence shown to 39 Nm (29 ft. lbs.).
9. Oil pump assembly [6]
10. Oil strainer and rubber ring [5]
11. Oil pipe and rubber ring [4]





12. Oil pan [3]
a. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. Apply a correct width bead of sealant (TB1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead.
The oil pan must be installed within 5 minutes after sealant application.
^ Tighten the bolts and nuts to 10 Nm (87 inch lbs.).
13. Cylinder head gasket [2]
14. Cylinder head assembly [1]