Installation

INSTALLATION





CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

1) Position the crankshaft on the #2 and #4 cylinder block.





2) Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block
Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent

CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.





3) Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure (LH side).
Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)





4) Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure (RH side)
Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)





5) Tighten LH side bolts (A) - (D) for a further 90° in alphabetical order.





6) Tighten RH side bolts (E)-(J) for a further 90° in alphabetical order.





7) Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure.
Tightening torque:
(A)-(G): 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)





8) Install the rear oil seal using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER
9) Position the top ring gap at (A) or (B) in the figure.





10) Position the second ring gap at 180° apart from the top ring gap.





11) Position the expander gap at (C) in the figure.





12) Position the lower rail gap at (D) in the figure.





13) Align the lower rail rotation stopper (F) with the hole (E) in the side of piston.





14) Position the upper rail gap at (G) in the figure.

NOTE:
- Ensure the ring gaps do not face the same direction.
- Ensure ring gaps are not within the piston skirt area.





15) Installing the circlip:
Install the circlips in piston holes located opposite of the service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

NOTE: Use new circlips.





CAUTION: Piston front mark faces towards the front of the engine.





16) Installing the piston:
a) Turn the cylinder block so that #1 and #2 cylinders face upward.
b) Using ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET





c) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.
ST2 398744300 PISTON GUIDE
17) Installing piston pin:





a) Insert ST3 into service hole to align piston pin hole with connecting rod small end.

CAUTION: Apply a coat of engine oil to ST3 before insertion.

ST3 499017100 PISTON PIN GUIDE

b) Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole.





c) Install the circlip using ST.
ST 499897200 PISTON SNAP RING PLIERS

CAUTION: Use new circlips.





d) Apply fluid packing around the service hole plug.
Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent





e) Install the service hole plug and gasket.

CAUTION: Use a new gasket.





f) Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
18) Install the water pipe.
19) Install the baffle plate.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
20) Install the oil strainer and O-ring
Tightening torque: 10 Nm (1.0 kgf-m, 7 ft. lbs.)
21) Install the oil strainer stay.





22) Apply fluid packing to matching surfaces and install the oil pan.
Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent





23) Apply fluid packing to matching surfaces and install the oil separator cover.
Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent





24) Install the drive plate. (AT vehicles)
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque: 72 Nm (7.3 kgf-m, 52.8 ft. lbs.)
25) Install the flywheel. (MT vehicles)
26) Install the clutch disc and cover. (MT vehicles)
27) Installation of oil pump:





a) Discard the front oil seal after removal. Replace with a new one using ST.
ST 499587100 OIL SEAL INSTALLER





b) Apply fluid packing to the matching surface of oil pump.
Fluid packing: THREE BOND 1215 (Part No. 004403007) or equivalent





c) Apply a coat of engine oil to the inside of the oil seal.
d) Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)

CAUTION:
- Do not forget to install the O-ring and seal when installing the oil pump.
- Align the flat surface of oil pump's inner rotor with crankshaft before installation.





28) Install the water pump and gasket.
Tightening torque:
First; 12 Nm (1.2 kgf-m, 8.7 ft. lbs.)
Second: 12 Nm (1.2 kgf-m, 8.7 ft. lbs.)

CAUTION:
- Be sure to use a new gasket.
- When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure.

29) Install the water by-pass pipe for heater.





30) Install the oil cooler.
Tightening torque:
T1: 55 Nm (5.5 kgf-m, 40 ft. lbs.)
T2: 70 Nm (7.0 kgf-m, 50.6 ft. lbs.)
T3: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
31) Install the oil filter using ST.
ST 498547000 OIL FILTER WRENCH





32) Install the water by-pass pipe between oil cooler and water pump.
33) Install the water pipe.

NOTE: Always use a new O-ring.

34) Install the cylinder head assembly.
35) Install the oil level gauge guide and tighten the attaching bolt (left side only).
36) Install the rocker cover.
37) Install the crankshaft sprocket.
38) Install the camshaft sprocket.
39) Install the timing belt assembly.
40) Install the belt cover.
41) Install the crankshaft pulley.
42) Install the generator and A/C compressor brackets on cylinder head.
43) Install the V-belt.
44) Install the intake manifold.