Assembly
PISTONSOil before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
If The Crankshaft Is Already Installed
1. Set the crankshaft to BDC for each cylinder.
2. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
3. Position the arrow and the mark facing the timing belt side of the engine.
4. 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 the rings from expanding before entering the cylinder bore.
5. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
6. Check the connecting rod bearing clearance with plastigage.
7. Apply engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 20 Nm (2.0 kgf.m, 14 ft. lbs.).
8. Mark the connecting rod and bolt head as shown.
9. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (Turn the bolt 90°).
If The Crankshaft Is Not Installed
1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
2. Position the arrow and the mark facing the timing belt side of the engine.
3. 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 the rings from expanding before entering the cylinder bore.
4. Position all pistons at top dead center.
CRANKSHAFT AND BALANCER SHAFTS
Oil before installing the crankshaft, apply a coat of engine oil to the main bearings, rod bearings and balancer shaft bearings.
1. Install the bearing halves in the cylinder block and connecting rods.
2. Hold the crankshaft so rod journal No.2 and rod journal No. 3 are straight up.
3. Install the thrust washers in the No. 4 journal of the cylinder block.
4. Lower the crankshaft into the block, seating the rod journals into connecting rod No. 1 and connecting rod No. 4. Install the connecting rod caps and bolts finger tight.
5. Rotate the crankshaft clockwise, seat the journals into connecting rod No. 2 and connecting rod No. 3. Install the connecting rod caps and bolts finger tight. Install caps so the bearing recess is on the same side as the recess in the rod.
6. Check the connecting rod bearing clearance with plastigage.
7. Apply engine oil to the bolt threads, then install the rod caps with bearings, and torque the bolts to 20 Nm (2.0 kgs.m, 14 ft. lbs.).
8. Mark the connecting rod and bolt head as shown.
9. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (Turn the bolt 90°).
10. Install the main bearing caps and bearing cap bridge. Coat the bolt threads with engine oil.
11. Check clearances with plastigage, then tighten the 11 mm bolts in two steps. In the first step, tighten all bolts in sequence to about 29 Nm (3.0 kgs m, 22 ft. lbs.): in the final step, tighten in same sequence to 78 Nm (8.0 kgs m, 58 ft. lbs.).
12. Tighten the 6 mm bolts in sequence to 12 Nm (1.2 kgs.m, 8.7 ft. lbs.).
CAUTION: Whenever any crankshaft 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. The seal mating surface on the right side cover should be dry. Apply a light coat of oil to the crankshaft and to the lip of the seal.
14. Drive the crankshaft oil seal squarely into the right side cover.
15. Confirm that the clearance is equal all the way around with a feeler gauge.
Clearance: 0.5 - 0.8 mm (0.02 - 0.03 inch)
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 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 the liquid gasket.Instead, reapply liquid gasket after removing the old residue.
^ After assembly, wait at least 30 minutes before filling the engine with oil.
16. Apply liquid gasket to the block mating surface of the right side cover, then install it on the cylinder block.
17. Insert the balancer shahs into the block, then install the retainer to the front balancer shaft and block.
18. Apply liquid gasket to the oil pump mating surface of the block, then install the oil pump on the cylinder block.
- Apply grease to the lips of the oil seals.
Then, install the oil pump while aligning the inner rotor with the crankshaft. When the pump is in place, clean any excess grease off the crankshaft and the balancer shah, then check that the oil seal lips are not distorted.
19. Install the baffle plate, then install the oil screen.
20. Hold the front balancer shaft with a screwdriver, then install the balancer belt driven pulley.
21. Before installing the balancer driven gear and the balancer gear case, apply molybdenum disulfide to the thrust surfaces of the balancer gears as shown.
22. Hold the rear balancer shaft with a 6 x 100 mm bolt, then install the balancer driven gear.
23. Install the balancer gear case to the oil pump.
NOTE: Align the groove on the pulley edge to the pointer on the gear case while holding the rear balancer with 6 x 100 mm bolt, then install the gear case.
24. Check the alignment of the pointers after installing the gear case.
25. Clean and dry the cylinder block mating surfaces.
26. Apply liquid gasket part No. 08718 - 0001 or 08718 - 0003 evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes. Install the oil pan.
NOTE:
^ Apply liquid gasket 4 mm wide.
^ Apply liquid gasket doubly to the jointing point of the liquid gasket.
27. Tighten the bolts/nuts in two or three steps. In the final step, tighten all bolts/nuts, in sequence to 12 Nm (1.2 kgs.m, 8.7 ft. lbs.).
CRANKSHAFT AND BALANCER SHAFT OIL SEALS
NOTE: The crankshaft and front balancer shaft oil seal housing surface should be dry.
Apply a light coat of grease to the crankshaft, the balancer shaft and to the lips of the seals.
1. Using the special tool, drive in the crankshaft oil 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. Using the special tool, press in the front balancer shaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the balancer shaft, and check that the oil seal lip is not distorted.
3. Using the special tool, drive the crankshaft oil seal into the right side cover to the point where the clearance between the bottom of the crankshaft oil seal and right side cover is 0.5 - 0.8 mm (0.02 - 0.03 inch).
NOTE: Align the hole in the driver attachment with the pin on the crankshaft.