Assembly

REASSEMBLY





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, O-rings and oil seals with new parts.

1. ASSEMBLE PISTON AND CONNECTING ROD
a. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.





b. Gradually heat the piston to about 60°C (140°F).





c. Coat the piston pin with engine oil.
d. Position the piston front mark with respect to the outside mark on the connecting rod as shown in the diagram.

NOTICE: The installation directions of the piston and connecting row are different for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".

e. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.





f. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.





2. INSTALL PISTON RINGS
a. Install the oil ring expander and 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.








c. Position the piston rings so that the ring ends are as shown.

NOTICE: Do not align the ring ends.





3. INSTALL BEARINGS
a. Align the bearing claw with the groove of the connecting rod or connecting cap.
b. install the bearings in the connecting rod and connecting rod cap.





4. INSTALL MAIN BEARINGS

HINT:
- Main bearings come in widths of 19.5 mm (0.768 inch) and 22.5 mm (0.886 inch). Install the 22.5 mm (0.886 inch) bearings in the No.1 and No.5 cylinder block journal positions with the main bearing cap. Install the 19.5 mm (0.768 inch) bearings in the other 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 5 upper bearings.





b. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

HINT: A number is marked on each main bearing cap to indicate the installation position.





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





7. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK
a. Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.





b. Install the 5 main bearing caps in their proper locations.





HINT: Place the bearing caps level and let them return to their original position by their own weight.

NOTICE: Do not install the main bearing cap by tapping it.





8. INSTALL MAIN BEARING CAP BOLTS

HINT:
- The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
- If any one 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 20 main bearing cap bolts in several passes, in the sequence shown.

Torque: 27 Nm (20 ft. lbs.)





If any one 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 bolt 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.





f. Install a new seal washer to the main bearing cap bolt.
g. Install and uniformly tighten the 10 main bearing cap bolts.

Torque: 49 Nm (36 ft. lbs.)

h. Check that the crankshaft turns smoothly.
9. CHECK CRANKSHAFT THRUST CLEARANCE





10. INSTALL PISTON AND CONNECTING ROD ASSEMBLES
Using a piston ring compressor, push the correctly number piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTICE: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".





11. PLACE CONNECTING ROD CAP ON CONNECTING ROD
a. Match the numbered connecting rod cap with the connecting rod.
b. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.





c. Check that the outside mark of the connecting rod cap is facing in correct direction.





12. INSTALL CONNECTING ROD CAP BOLTS

HINT: The connecting rod cap bolts are tightened in 2 progressive steps.





If any one 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: 25 Nm (18 ft. lbs.)

If any one 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 bolt with paint.
d. Retighten the cap bolts 90� as shown.
e. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
13. CHECK CONNECTING ROD THRUST CLEARANCE
14. INSTALL REAR OIL SEAL RETAINER
a. Remove any old packing Formed In Place Gasket (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 inch) opening.
- 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.





c. Install a new O-ring to the cylinder block.
d. Install the oil seal retainer with the 7 bolts.

Torque: 8.0 Nm (71 inch lbs.)





15. INSTALL ENGINE COOLANT DRAIN UNIONS
a. Apply seal packing to 2 or 3 threads.

Seal packing: Part No. 08826-00100 or equivalent





b. Install the RH and LH drain unions.

Torque: 49 Nm (36 ft. lbs.)

HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

16. INSTALL WATER SEAL PLATE
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the seal plate and cylinder block.
- Using a razor blade and gasket scraper, remove, 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 seal plate 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 inch) opening.
- 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.
c. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.

Torque: 14 Nm (10 ft. lbs.)

17. INSTALL OIL PUMP
18. INSTALL OIL STRAINER
19. INSTALL NO.1 OIL PAN
20. INSTALL OIL PAN BAFFLE PLATE
21. INSTALL NO.2 OIL PAN
22. INSTALL WATER PUMP





23. INSTALL ENGINE WIRE
a. Install the engine wire to the LH side of the cylinder block with the 2 bolts.
b. Install the engine wire cover with the 3 bolts.





c. Install the engine wire to the RH side of the cylinder block with the 2 bolts.
d. Connect these connectors:
- Crankshaft position sensor connector
- Oil pressure switch connector
- Oil level sensor switch connector
24. INSTALL KNOCK SENSORS
25. INSTALL STARTER





26. INSTALL WATER BYPASS PIPE
a. Install a new O-ring to the water bypass pipe.
b. Apply soapy water to the O-ring.
c. Push the water bypass pipe end into the pipe hole of the water pump.
d. Install the water bypass pipe with the 2 bolts.

Torque: 18 Nm (13 ft. lbs.)

e. Install the engine wire clamp to the bracket on the water bypass pipe.





27. INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the 4 bolts.

Torque: 36 Nm (27 ft. lbs.)

HINT: The RH mounting bracket is marked with "R".





28. INSTALL LH ENGINE MOUNTING BRACKET
a. Install the mounting bracket with the 4 bolts.

HINT: The LH mounting bracket is marked with "L".

b. Install the engine wire to the mounting bracket with bolt.

Torque: 36 Nm (27 ft. lbs.)

b. Install the engine wire to the mounting bracket with the bolt.
29. INSTALL CYLINDER HEADS
30. INSTALL TIMING BELT AND PULLEYS
31. DISCONNECT ENGINE FROM ENGINE STAND