Assembly
CYLINDER BLOCK ASSEMBLYHINT:
- Thoroughly clean all parts to be assembled
- Before installing the parts, apply fresh 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 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
- Upper bearings have an oil groove and oil holes; lower bearings do not.
(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.
NOTICE: lnstall the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw groove of the main bearing cap. and push in the 4 lower bearings.
HINT: A number is marked on each main bearing cap to indicate the installation position.
2. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.2 journal position of the cylinder block with the oil grooves facing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS
A. Place main bearing caps and lower thrust washer on cylinder block
(a) Install the 2 thrust washers on the No.2 bearing cap with the grooves facing outward.
(b) Temporarily place the 4 main bearing caps level and set them in their proper locations.
(c) Apply a light coat of engine oil on the threads and under the main bearing cap bolts for the 12 pointed head.
(d) Temporarily install the 8 main bearing cap bolts to the inside positions.
(e) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
B. Install 12 pointed head main bearing cap bolts
HINT:
- The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d).
- If any of the main bearing cap bolts is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
(b) Install and uniformly tighten the 16 main bearing cap bolts, in several passes. in the sequence shown. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf)
If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolts with paint.
(d) Retighten the main bearing cap bolts by 90° in the numerical order shown.
(e) Check that the painted mark is now at a 90° angle to the front.
C. Install hexagon head main bearing cap bolts
(a) Install a new seal washer to the main bearing cap bolt.
(b) Install and uniformly tighten the 8 main bearing cap bolts, in several passes, in the sequence shown. Torque: 27 N.m (275 kgf.cm, 20 ft.lbf
(c) Check that the crankshaft turns smoothly.
5. CHECK CRANKSHAFT THRUST CLEARANCE
(See step 5 in cylinder block disassembly)
6. INSTALL PISTON AND CONNECTING ROD ASSEMBLES
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.
HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".
7. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod
(a) Match the numbered connecting rod cap with the connecting rod.
(b) Align the pin dowels of the connecting rod cap with the pins of the connecting rod. and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is facing in the correct direction.
B. Install connecting rod cap bolts
HINT:
The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
If any of the connecting rod cap bolts is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolts with paint.
(d) Retighten the cap bolts by 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.
8. CHECK CONNECTING ROD THRUST CLEARANCE
(See step 2 in cylinder block disassembly)
9. 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 oil seal retainer and cylinder block.
- Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
- 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 oil seal 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.
- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
C. Immediately remove nozzle from the tube and reinstall cap.
(c) Install the oil seal retainer with the 6 bolts Uniformly tighten the bolt in several passes, in the sequence shown.
Torque: 8 N.m (80 kgf.cm. 69 in.lbf)