Part 2
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)
Oil pump
1. Apply silicone sealant to the contact surface of the oil pump.
Thickness: 1 - 2 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 within five minutes of applying the sealant.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
Bolt length
(A): 40 mm (1.57 inch)
(B): 25 mm (0.98 inch)
5. Cut away the portion of the gasket that projects toward the oil pan.
Oil baffle
Install the oil baffle and tighten the bolts gradually 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 the 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.)
(B): 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.)
Backing plate, drive plate, adapter
CAUTION: Verify that the adapter and the backing plate are mounted in the directions shown. 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 lock 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 figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note
Disassembly Note
Connecting rod cap
Before removing the connecting rod caps, measure the connecting rod side clearance.
Piston and connecting rod assembly
1. Before removing the piston and connecting rod assembly, measure the connecting rod bearing oil clearance by using Plastigage.
2. Remove the Plastigage from journals and bearings.
3. Face the front of the engine upward as shown.
4. Remove the connecting rod caps and bearings.
5. Use the handle of a hammer to push the piston and connecting rod assembly through the top of the cylinder block.
Piston ring
Remove the piston rings by using a piston ring expander.
Piston pin
1. Before disassembling the piston and connecting rod, check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
2. Use the following Special Service Tool (SST) and a press.
3. Assemble the SST into the piston pin as shown.
4. Verify that the SST fits squarely into the piston before pressing.
5. Set the piston and connecting rod on the SST as shown.
6. Press out the piston pin. While removing the piston pin, note the pressing pressure. If it is less than 3,923 N (880 lbf), replace the piston pin or connecting rod.
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 the order shown.
3. Insert a screwdriver only at the points shown.
4. Remove the lower cylinder block.
Assembly Note
Lower cylinder block
1. Measure the main bearing oil clearances as described below.
Oil clearance inspection
1) Install the upper main bearings and upper thrust bearings.
NOTE: No. 4 bearing is wider than other bearings.
2) Install the lower cylinder block along with the lower main bearings and thrust bearings.
3) Measure the lower cylinder block bolt length. Replace the lower cylinder block bolt if necessary.
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)
4) Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
5) Tighten the bolts in two or three steps in the order shown.
Tightening torque
Bolt(A) and (B): 23.1 - 25.9 Nm (17.0 - 19.1 ft. lbs.)
Bolts (C): 18.2 - 21.0 Nm (13.4 - 15.5 ft. lbs.)
NOTE:
- Bolts (A) are marked "4" on the head.
- Bolts (B) are marked "I" on the head.
- Bolts (C) are not marked on the head.
6) Put a paint mark on the lower cylinder block next to the (A), (B), (C) bolt flange marks as shown.
7) Using the marks as a reference, further tighten the bolts (A), (B), (C) in the order shown.
Main bolt (A) (No. 4 journal): 75° - 85°
Main bolt (B) (No. 1 - No. 3 journals): 65° - 75°
Sub bolt (C): 55° - 65°
8) Tighten the bolts till the mark on each bolt flange aligns with the corresponding paint mark.
9) Further tighten each bolt by performing steps (6), (7).
10) After tightening, measure the cylinder block No.1 - No.4 journal bore diameter.
11) Subtract the main journal diameter from the bore diameter.
12) If the oil clearance exceeds the maximum, replace the bearing or grind the crankshaft and install undersize main bearings.
Oil clearance: 0.037 - 0.057 mm (0.0015 - 0.0022 inch)
Maximum: 0.064 mm (0.0025 inch)
Main Journal Diameter
Standard: 61.938 - 61.955 mm (2.4385 - 2.4391 inch)
0.25 mm (0.01 inch) undersize: 61.688 - 61.705 mm (2.4287 - 2.4293 inch)
13) Remove the lower cylinder block.
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)
Other: 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.
6) Apply clean engine oil to the threads and seat faces of the lower cylinder block bolts.
7) Tighten the main bolts (A), (B) and sub bolts (C) as in steps 1 - (5) - 1 - (9).
8) Tighten the lower cylinder block bolts (D) in the order shown.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
3. Inspect the crankshaft end play.
End play: 0.08 - 0.282 mm (0.0032 - 0.0111 inch)
Maximum: 0.32 mm (0.0126 inch)
4. If the end play exceeds the maximum, grind the crankshaft and install oversize thrust bearings or replace the crankshaft and thrust bearing.
Thrust bearing width
Standard: 2.000 - 2.050 mm (0.0788 - 0.0807 inch)
0.25 mm (0.01 inch) oversize: 2.125 - 2.175 mm (0.0837 - 0.0856 inch)
0.50 mm (0.02 inch) oversize: 2.250 - 2.300 mm (0.0886 - 0.0905 inch)
5. Apply clean engine oil to the lip of the new rear oil seal.
6. Push the rear oil seal slightly in by hand.
7. Tap the oil seal in evenly with the SST and a hammer.
Protrusion: 0 - 0.7 mm (0 - 0.03 inch)
Connecting rod
1. Assemble the SSTs (setting tool set, piston pinch) to the piston pin.
2. Apply clean engine oil to the piston pin.
3. Set the SST (stopper bolt) so that the depth L is as specified.
Depth L: 61.5 mm (2.421 inch)
4. Tighten the locknut.
5. Assemble the piston and the connecting rod.
6. Insert the SST (setting tool set, piston pinch) assembled in step 1 into the piston pin hole.
7. Mount the piston and connecting rod onto the SST (support block body).
8. Verify that SST fits squarely into the piston before pressing.
9. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt).
10. While inserting the piston pin, note the pressing force. If it is not within specification, replace the piston pin and/or the connecting rod.
Pressing force: 3,923 - 12,748 N (880 - 2,860 lbf)
11. Check the connecting rod oscillation torque.
Piston ring
1. Install the three-piece oil rings on the pistons.
1) Apply clean engine oil to the oil ring spacer and rails.
2) Install the oil ring spacer with the ends facing upward.
NOTE: The upper and lower rails are the same. They can be installed with either face upward.
3) Install the upper and lower rails.
2. Verify that the spacer tang separates the rails, and that the rails turn smoothly in both directions.,
3. Using a piston ring expander, install the second ring with the scraper face downward.
4. Using a piston ring expander, install the top ring.
5. Apply clean engine oil to the piston rings.
6. Position the end gap of oil ring as shown.
Piston and connecting rod assembly
1. Rotate the engine on the engine stand as shown.
NOTE: Assembly is easier if the pistons are installed with the crankpin at the BDC position.
2. Remove any foreign material and oil from the connecting rod journals and bearings.
3. Install the upper connecting rod bearings in the connecting rods.
4. Apply clean engine oil to the cylinder walls, pistons, piston rings and connecting rod cap bolts.
5. Check the piston rings for proper end gap positioning.
6. Insert the piston assemblies into the cylinder block with the (L) mark (left bank) and the (R) mark (right bank) facing the front of the engine. Use a piston ring compressor to install.
7. Tap the piston ring compressor by using a plastic hammer.
8. Retighten the piston ring compressor.
9. Use the handle of a hammer to push the piston and connecting rod into the cylinder until the connecting rod bearing fully contacts the crank pin.
Connecting rod cap
1. Measure the connecting rod bearing oil clearances as follows.
1) Measure the oil clearance with the connecting rod in BDC position.
2) Do not rotate the crankshaft when measuring the oil clearances.
3) Position Plastigage atop the journals in the axial direction.
4) Remove any foreign material and oil from the lower connecting rod bearing and connecting rod cap.
5) Install the connecting rod bearing in the cap.
6) Measure the length of connecting rod cap bolt. Replace it if the length exceeds the maximum.
Length: 46.7 - 47.3 mm (1.84 - 1.86 inch)
Maximum: 48.0 mm (1.89 inch)
7) Apply clean engine oil to the threads and seat faces of the connecting rod cap bolts.
8) Install the connecting rod cap.
9) Tighten the connecting rod cap bolts.
Tightening torque:
22.1 - 26.9 Nm (16.3 - 19.8 ft. lbs.)
10) Put a paint mark on each bolt head.
11) Using this mark as a reference, tighten the bolts 83° - 97°.
12) Remove the connecting rod cap.
13) Measure the Plastigage at each journal at the widest point for the smallest clearance, and the narrowest point for the largest clearance.
Oil clearance: 0.023 - 0.043 mm (0.0010 - 0.0016 inch)
Maximum: 0.08 mm (0.0031 inch)
14) If the clearance exceeds the maximum, grind the crankshaft and install undersize bearings.
2. Install the connecting rod caps as follows.
1) Remove the Plastigage from the journals and bearings.
2) Apply clean engine oil to the connecting rod bearings.
3) Install the connecting rod bearings and caps.
4) Apply clean engine oil to the threads and seat faces of the cap bolts and tighten them as in steps 1 - (9) - 1 - (11).
5) Verify that the crankshaft rotates smoothly by hand.
3. Measure the connecting rod side clearances.
1) Measure each connecting rod side clearance.
Side clearance: 0.178 - 0.330 mm (0.0071 - 0.0129 inch)
Maximum: 0.40 mm (0.0157 inch)
2) If the clearance exceeds the maximum, replace the connecting rod and cap assembly.