Part 2
Lysholm compressor bracket
1. Install the Lysholm compressor bracket and hand tighten bolts (A) until the Lysholm compressor bracket seats fully to the cylinder block
2. Tighten the bolts in the order shown.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
Water outlet pipe
1. Install the water outlet pipe and hand tighten the bolts in the order shown.
2. Tighten the bolts in the order shown.
Tightening torque
(1), (2):
19 - 25 Nm (14 - 18 ft. lbs.)
(3):
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
Camshaft pulley
1. Install the camshaft pulley so that the "R" mark (RH) can be seen and the groove aligns with the camshaft knock pin.
2. Install the camshaft pulley so that the "L" mark (LH) can be seen and the groove aligns with the camshaft knock pin.
3. Apply clean engine oil to the camshaft pulley lock bolt threads.
4. Hold the camshaft by using a wrench on the cast hexagon as shown, and tighten the camshaft pulley lock bolt.
Tightening torque:
123 - 140 Nm (90.5 - 103 ft. lbs.)
5. Verify that the engine is in cold condition.
6. Verify that the pistons are not at TDC.
7. Turn the camshaft to set the cam lobe right over. Measure the valve clearance.
Valve clearance (Engine cold)
Standard
IN: 0.27 - 0.33 mm (0.011 - 0.012 inch)
EX: 0.27 - 0.33 mm (0.011 - 0.012 inch)
8. If the valve clearance exceed the standard, replace the adjustment shim in the order shown below.
1) Install the timing belt pulley and bolt.
2) Turn the crankshaft clockwise so that the No.1 piston is at TDC.
3) Turn the crankshaft approximately 180° clockwise.
4) Remove the camshaft cap bolts as necessary.
1): For RH exhaust side adjustment shim removal
2): For RH intake side adjustment shim removal
3): For LH intake side adjustment shim removal
4): For LH exhaust side adjustment shim removal
5) Install the SST as shown.
Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)
6) Align the marks on the SSTs (shaft and shaft clamp).
7) Face the SST (body) toward the center of the cylinder head, and mount it on the camshaft using the camshaft cap bolt holes.
8) Tighten bolts (A) to secure the SST (shaft).
9) Face the notch of the tappet so that a fine screwdriver can be inserted.
10) Set the SST on the tappet by its notch.
11) Tighten bolt (A to secure the SST (body).
12) Tighten bolt A) and press down the tappet.
13) Using a fine screwdriver, pry up the adjustment shim through the notch on the tappet. Remove the shim by using a magnet.
14) Select proper adjustment shim.
New adjustment shim:
= Removed shim thickness + Measured valve clearance
- Standard valve clearance (0.3 mm (0.012 inch)
15) Push the selected shim into the tappet.
16) Loosen bolt (C) to allow the tappet to move up.
17) Loosen bolt (B) and remove the SST (body).
18) Remove the SSTs and tighten the camshaft cap bolts.
Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)
19) Check the valve clearance.
Cylinder head cover
1. Apply silicone sealant to the shaded area as shown.
2. Apply silicone sealant to the cylinder head cover as shown.
Thickness:
1.0 - 2.0 mm (0.04 - 0.07 inch)
3. Install the new cylinder head cover gasket into the cylinder need cover.
4. Apply silicone sealant to the shaded area as shown.
Thickness:
1.5 - 2.5 mm (0.06 - 0.09 inch)
5. Install the cylinder head cover and tighten the bolts in five or six steps in the order shown.
Tightening torque:
5.0 - 8.8 Nm (44 - 78 inch lbs.)
6. Retighten RH (5), (6) and LH (5), (6) cylinder head cover bolts.
Tightening torque:
5.0 - 8.8 Nm (44 - 78 inch lbs.)
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the image, referring to Disassembly Note.
2. Assemble in the reverse order of assembly, referring to Assembly Note.
Disassembly Note
Backing plate, drive plate, adapter
1. Hold the drive plate by using the Special Service Tool (SST).
2. Remove the drive plate bolts in two or three steps in the order shown.
3. Remove the backing plate, drive plate, and adapter.
Knock sensor
Remove the knock sensor by using the SST.
Oil pan
1. Remove the oil pan bolts.
2. Turn a bolt into the special bolt hole as shown to make a small gap between the oil pan and the lower cylinder block.
3. Insert a screwdriver or seal cutter between the cylinder block and the oil pan to-separate them.
4. Remove the oil pan.
Front oil seal
Remove the oil seal by using a screwdriver protected with a rag.
Assembly Note
Front oil seal
1. Apply clean engine oil to the new oil seal.
2. Install the oil seal into the oil pump body by hand.
3. Press the oil seal into the oil pump body by using a SST.
Protrusion:
0 - 0.7 mm (0 - 0.03 inch)
Slope:
0.4 mm (0.016 inch) max.
Oil pump
1. Apply silicone sealant to the contact surface of the oil pump.
Thickness:
1.0 - 2.0 mm (0.04 - 0.07 inch)
2. Apply clean engine oil to the new O-ring and install it into the oil pump body.
3. Apply clean engine oil to the oil seal lip.
4. Install the oil pump and tighten the bolts in two or three steps in the order shown.
NOTE: Install the auto tensioner and vacuum pump at the same time that you install the oil pump. The auto tensioner will have to be removed temporarily when the timing belt is installed, but tighten it to the specified torque anyway.
Tightening torque:
(A) 22 - 30 Nm (16 - 22 ft. lbs.)
19 - 25 Nm (14 - 18 ft. lbs.)
Water pump
Install a new rubber seal and the water pump.
NOTE: When installing the No.3 engine mount bracket, tighten it to the specified torque.
Oil baffle
Install the oil baffle and tighten the bolts in two or three steps in the order shown.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
Oil strainer
1. Install a new gasket and the oil strainer onto the oil pump body.
2. Tighten bolts (A) first.
Tightening torque:
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
Oil pan
1. Remove the old sealant from the oil pan bolts and bolt holes in the lower cylinder block.
CAUTION: If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage.
2. Apply silicone sealant to the oil pan along the inside of the bolt holes, and overlap the ends.
3. Install the oil pan within five minutes of applying the sealant.
Tightening torque:
(A) 19 - 25 Nm (14 - 18 ft. lbs.)
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
Knock sensor
Install the knock sensor by using the SST.
Tightening torque:
20 - 34 Nm (15 - 25 ft. lbs.)
Oil pressure switch
1. Apply sealant to the oil pressure switch threads as shown.
2. Install the oil pressure switch.
Tightening torque:
12 - 17 Nm (8.7 - 13 ft. lbs.)
Backing plate, drive plate, adapter
CAUTION: Verify that the adapter and the backing plate are mounted in the specified directions. Incorrect mounting can damage the engine and transaxle.
1. Install the following parts to the crankshaft.
1) Adapter
2) Drive plate
3) Backing plate
2. Hand tighten the drive plate bolts.
3. Hold the drive plate by using the SST.
4. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
61 - 67 Nm (45 - 49 ft. lbs.)
CYLINDER BLOCK (INTERNAL PARTS)
Lower Engine:
1. Disassemble in the order shown in the image, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
Disassembly Note
Piston and connecting rod assembly
Before removing the piston and connecting rod assembly, measure the connecting rod side clearance and connecting rod bearing oil clearance.
1) Measure the connecting rod side clearance.
2) Measure the connecting rod bearing oil clearance.
Piston pin
Remove the piston pin by using the Special Service Tool (SST).
Lower cylinder block
1. Before removing the lower cylinder block, measure the crankshaft end play.
2. Loosen the lower cylinder block bolts in two or three steps in order shown.
3. Insert a screwdriver only at the points as shown.
4. Remove the lower cylinder block.
Assembly Note
Lower cylinder block
NOTE:
- Lower cylinder block bolts (A) are marked "4" on the head.
- Lower cylinder block bolts (B) are marked "1" on the head.
- Lower cylinder block bolts (C) have no mark on the head.
1. Measure the length of lower cylinder block bolts.
Replace any that exceed the maximum length.
Lower Cylinder Block Bolts:
Bolt (A) and (B)
Length: 135.7 - 136.3 mm (5.343 - 5.366 inch)
Maximum: 138.5 mm (5.453 inch)
Bolt (C)
Length: 119.7 - 120.3 mm (4.713 - 4.736 inch)
Maximum: 121.0 mm (4.764 inch)
2. Install the lower cylinder block as follows:
1) Install the upper thrust bearings in the upper cylinder block.
2) Apply clean engine oil to the main bearings, thrust bearings, and main journals.
3) Install the crankshaft in the cylinder block.
4) Apply silicone sealant to the contact surface as shown.
Thickness:
Groove: 2.5 - 3.5 mm (0.10 - 0.13 inch)
Others: 0.5 - 1.5 mm (0.02 - 0.05 inch)
5) Install the lower cylinder block, lower main bearings, and lower thrust bearings within five minutes of applying the sealant. Wipe off excessive seal from matching surface of the upper and lower cylinder blocks (area (X)).
6) Apply clean engine oil to the threads and seat faces of the lower cylinder block bolts.
Lower Cylinder Block Torque Sequence:
7) Tighten bolts (A) and (B) in two or three steps in the order shown.
Tightening torque:
23.1 - 25.9 Nm (17.0 - 19.1 ft. lbs.)
Lower Cylinder Block Torque Sequence:
8) Tighten bolts (C) in two or three steps in the order shown.
Tightening torque:
18.2 - 21.0 Nm (13.4 - 15.5 ft. lbs.)
9) Put a paint mark on the lower cylinder block next to the bolt flange marks as shown.
10) Using the marks as a reference, further tighten the bolts in the order shown.
11) Tighten the bolts till the mark on each bolt flange aligns with the corresponding paint mark.
12) Further tighten each bolt by performing step (9), (10).
Torque Sequence:
13) Tighten lower cylinder block bolts (D) in the order shown.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
3. Apply clean engine oil to the new rear oil seal lip.
4. Push the rear oil seal slightly in by hand.
5. Tap the oil seal in evenly by using a SST and a hammer.
Protrusion: 0 - 0.7 mm (0 - 0.03 inch)
Slope: 0.4 mm (0.016 inch) max.
Piston pin
1. Install the piston pin clip into the clip groove in the piston.
2. Assemble the piston and the connecting rod in the direction from which they were disassembled.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin from the side opposite the clip.
5. Install the piston pin until the pin contacts the clip. If the pin cannot be installed easily, heat the piston.
6. Install the second clip into the clip groove in the piston.
7. Check the connecting rod oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
Piston and connecting rod assembly
1. Install the three-piece oil rings on the pistons. Face the scraper side of the second ring downward.
2. Position the end gap of each ring as shown.
3. Insert the piston assemblies into the cylinder block with the R mark (RH) and the L mark (LH) facing the front of the engine. Use a piston ring compressor to install.
4. Measure the length of connecting rod cap bolt. Replace it if the length exceeds the maximum.
Length: 46.7 - 47.3 mm (184 - 1.86 inch)
Maximum: 48.0 mm (1.89 inch)
5. Install the connecting rod cap as follows:
1) Apply clean engine oil to the connecting rod cap bolt threads.
2) Tighten the connecting rod cap bolts.
Tightening torque:
22.1 - 26.9 Nm (16.3 - 19.8 ft. lbs.)
3) Put a paint mark on each bolt head.
4) Using this mark as a reference, tighten the bolts 82.5° - 97.5°