Part 2
WARNING: Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
THERMOSTAT
1. Install the thermostat with the jiggle pin facing upward.
2. Install the new gasket with the printed side facing the cylinder head.
VALVE SEAL
The intake and exhaust valve seals are colored for identification.
IN: gray
EX: green
1. Assemble the SSTs as shown.
CAUTION:
- Using a hammer will damage the valve seal.
2. Using the SST, press the valve seal on by hand.
3. Measure the valve seal setting height.
Valve seal setting height:
10.82 mm (0.426 inch).
VALVE SPRING
Install the valve spring with the closer pitch toward the cylinder head.
VALVE KEEPER
Compress the valve spring by using the SST, and install the valve keepers.
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the image.
2. Assemble in the reverse order of disassembly.
DISASSEMBLY NOTE
BACKING PLATE, DRIVE PLATE, ADAPTER (ATX), FLYWHEEL (MTX)
1. Hold the drive plate (ATX) or flywheel (MTX) by using the SST.
2. Remove the drive plate lock bolts and remove the backing plate and adapter. (ATX)
3. Remove the flywheel lock bolts and remove the flywheel. (MTX)
OIL PAN
Separate the oil pan from the VRAS by using a scraper or a separator tool.
VRAS
Separate the VRAS from the cylinder block by using a scraper or a separator tool.
OIL PUMP
Remove the oil seal by using a screwdriver protected with a rag.
REAR COVER
Remove the oil seal by using a screwdriver protected with a rag.
ASSEMBLY NOTE
REAR COVER
1. Apply clean engine oil to the new oil seal.
2. Push the oil seal slightly in by hand.
3. Press the oil seal in evenly by using the SST.
Protrusion:
0 - 0.5 mm (0 - 0019 inch)
4. Apply silicone sealant to the rear cover as shown.
Thickness:
2 mm (0.079 inch)
5. Install the rear cover.
Tightening torque:
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
OIL PUMP
1. Apply clean engine oil to the new oil seal.
2. Push the oil seal slightly in by hand.
3. Press the oil seal in evenly by using the SST.
Protrusion:
0.5 - 1.0 mm (0.020 - 0.039 inch)
4. Install the new O-ring.
5. Apply silicone sealant to the oil pump body as shown.
Thickness:
1 - 2 mm (0.040 - 0.078 inch)
6. Install the oil pump.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
VRAS
1. Apply silicone sealant to the oil pump and rear cover mounting surfaces of the new oil pan gaskets, and install them.
2. Apply silicone sealant to the VRAS as shown.
Thickness:
2 - 3 mm (0.079 - 0.118 inch)
3. Install the VRAS.
4. Tighten the bolts in the order shown.
Tightening torque:
(1) - (8): 16 - 20 Nm (12 - 15 ft. lbs.)
(9) - (14): 7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
OIL PAN
1. Apply silicone sealant to the oil pan as shown.
Thickness:
2 - 3 mm (0.079 - 0.118 inch)
2. Install the oil pan.
Tightening torque:
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
BACKING PLATE, DRIVE PLATE, ADAPTER (ATX), FLYWHEEL (MTX)
1. Hold the drive plate (ATX) or flywheel (MTX) by using the SST.
2. Install the drive plate. (ATX)
3. Install the flywheel. (MTX)
Tightening torque:
97 - 102 Nm (71 - 75.9 ft. lbs.)
WATER PUMP
1. Verify that the rubber seal is securely fixed onto the water pump.
2. If not, remove the rubber seal and reinstall it with the bonding agent.
3. Install the water pump.
Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)
CYLINDER BLOCK (INTERNAL PARTS)
Lower Engine:
1. Disassemble in the order shown in the image.
2. Assemble in the reverse order of disassembly.
DISASSEMBLY NOTE
PISTON AND CONNECTING ROD ASSEMBLY
Before removing the piston and connecting rod assembly, inspect the following.
1. Connecting rod large end side clearance.
2. Connecting rod bearing oil clearance.
PISTON PIN
CAUTION:
- The connecting rods must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear.
NOTE:
- Mark the connecting rods to show their original positions.
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. Insert the SST into the piston pin as shown.
3. Mount the piston and connecting rod in the SST as shown.
4. Press out the piston pin.
MAIN BEARING CAP
1. Before removing the main bearing caps, measure the crankshaft end play.
2. Loosen the main bearing cap bolts in two or three steps in the order shown in the image.
3. Remove the main bearing caps.
CRANKSHAFT
Before removing the crankshaft, measure the main bearing oil clearances.
ASSEMBLY NOTE
MAIN BEARING CAP
Torque Sequence:
Tighten the main bearing cap bolts in two or three steps in the order shown.
Tightening torque:
54 - 58 Nm (40 - 43 ft. lbs.)
PISTON PIN
1. Set the piston pin on the SST as shown.
2. Apply clean engine oil to the piston pin.
3. Set the stopper bolt so that dimension L is as specified.
Dimension L:
61.4 mm (2.42 inch)
4. Insert the piston pin and SST assembled in step 1 into the piston and connecting rod assembly.
5. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt).
6. While inserting the piston pin, check the pressure force. If it is less than specification, replace the piston pin or the connecting rod.
Pressure force:
4.91 - 14.70 kN (1,100 - 3,300 lbs.)
7. Check the oscillation torque of the connecting rod.
PISTON AND CONNECTING ROD ASSEMBLY
1. Verify that the second ring is installed with the scraper face downward.
2. Position the end gap of each ring as shown.
3. Insert the piston and connecting rod assembly into the cylinder with the F mark facing the front of the engine.
4. Align the matching marks on the connecting rod and the connecting rod cap, install the connecting rod cap.
Tightening torque:
30 - 34 Nm (22 - 25 ft. lbs.)