Assembly

CYLINDER BLOCK ASSEMBLY

HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, 0-rings and oil seals with new parts.

1. INSTALL MAIN BEARINGS

HINT: Main bearings come in widths of 20 mm (0.79 in.) and 22 mm (0.87 in.). Install the 22 mm (0.87 in.) bearings in the No.1 cylinder block journal position with the main bearing caps. Install the 20 mm (0.79 in.) bearings in the other positions. Upper bearings have an oil holes lower bearings do not.

(a) Align the bearing claw with the claw groove of the main bearing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing cap.

2. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.2 journal position of the block with the oil grooves facing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK

4. INSTALL MAIN BEARING CAP AND LOWER THRUST WASHERS
A. Place main bearing cap and lower thrust washers on cylinder block
(a) Install the thrust washers on the No.2 journal position of the bearing cap with the grooves facing outward.

(b) Install the main bearing cap with the front mark facing forward.

B. Install main bearing cap bolts

HINT: The main bearing cap bolts are tightened in two progressive steps (steps (b) and (d)). If any main bearing cap bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the eight main bearing cap bolts in several passes, in the sequence shown.
Torque: 61 N.m (625 kgf.cm, 45 ft.lbf)
If any one of the main bearing cap bolts does not meet the torque specification, replace the cap bolt.

(d) Retighten the main bearing cap bolts 90° in the numerical order shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance.

5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

(b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

6. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod
(a) Match the numbered connecting rod cap with the connecting rod.
(b) Install the connecting rod cap with the front mark facing forward.
B. Install connecting rod cap nuts

HINT:
- The connecting rod cap nuts are tightened in two progressive steps (steps (b) and (d)).
- If any connecting rod bolt is broken or deformed, replace them.

(a) Apply a light of engine oil on the threads and under the nuts of the connecting rod cap.
(b) Using SST, install and alternately tighten the nuts of the connecting rod cap in several passes. SST 09011-38121
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
If any one of the connecting rod cap nuts does not meet the torque specification, replace the cap nut.

(d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance.
7. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer and cylinder block.
- Using a razor blade and gasket scraper. remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the retainer as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
- Install a nozzle that has been cut to a 2-3 mm (0.08-0.12 in.) opening.

HINT: Avoid applying an excessive amount to the surface.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.