Installation
INSTALLATION
1) Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
2) Position the crankshaft and O-ring on cylinder block RH.
NOTE:
Use new O-rings.
3) Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH.
NOTE:
^ Install within 5 min. after applying liquid gasket.
^ Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
4) Apply a coat of engine oil to the washer and bolt thread.
NOTE:
Use a new seal washer.
5) Tighten the 10 mm cylinder block connecting bolts on the LH side (A - D) in alphabetical order.
6) Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order.
7) Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
8) Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
9) Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
^ (A), (C): Angle tightening
Tightening angle:
90 degrees
^ (B), (D): Torque tightening
10) Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A - H) in alphabetical order.
12) Apply a coat of engine oil to the oil seal periphery and install the rear oil seal using ST1 and ST2.
NOTE:
Use a new rear oil seal.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
13) Position the top ring gap at (A) or (B) in the figure.
14) Position the second ring gap at 180 degrees on the reverse side the top ring gap.
15) Position the upper rail gap at (C) in the figure.
16) Align the upper rail spin stopper (E) to the side hole (D) on the piston.
17) Position the expander gap at (F) on the 180 degrees opposite direction of (C) in the figure.
18) Set the lower rail gap at position (G), located 120 degrees clockwise from (C).
NOTE:
^ Make sure ring gaps do not face the same direction.
^ Make sure ring gaps are not within the piston skirt area.
19) Install the snap ring.
Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side.
NOTE:
Use new snap rings.
20) Install the piston.
1) Set the parts so that the #1 and #2 cylinders are on the upper side.
2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
3) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.
ST2 498747300 PISTON GUIDE
NOTE:
Face the piston front mark towards the front of the engine.
21) Install the piston pin.
1) Apply a coat of engine oil to ST3.
2) Insert ST3 into the service hole to align piston pin hole with connecting rod small end.
ST3 499017100 PISTON PIN GUIDE
3) Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
4) Install the snap ring.
NOTE:
Use new snap rings.
5) Apply liquid gasket to the threaded portion of the service hole plug.
6) Install the service hole plug and gasket.
NOTE:
Use a new gasket.
7) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
8) Install the service hole cover.
NOTE:
Use new O-rings.
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
22) Install the water pipe assembly.
NOTE:
Use new O-rings.
23) Install the baffle plate.
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
24) Install the oil strainer.
NOTE:
Use new O-rings.
Tightening torque:
10 N.m (1.0 kgf-m, 7.4 ft-lb)
25) Tighten the oil strainer stay together with the baffle plate.
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
26) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan.
NOTE:
Install within 5 min. after applying liquid gasket.
27) Apply liquid gasket to the mating surfaces of the oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover.
NOTE:
^ Install within 5 min. after applying liquid gasket.
^ Use new oil separator cover.
28) Install the drive plate. (AT model)
29) Install the flywheel. (MT model)
30) Install the clutch disc and cover. (MT model)
31) Install the oil pump.
1) Using the ST, install the front oil seal.
ST 499587100 OIL SEAL INSTALLER
NOTE:
Use a new front oil seal.
2) Apply liquid gasket to the mating surfaces of oil pump.
NOTE:
Install within 5 min. after applying liquid gasket.
3) Apply a coat of engine oil to the inside of oil seal.
4) Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation.
NOTE:
^ Make sure the oil seal lip is not folded.
^ Align the flat surface of oil pump's inner rotor with crankshaft before installation.
^ Use new O-rings and oil seals.
^ Do not forget to assemble O-rings.
5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts)
32) Install the water pump and gasket.
NOTE:
^ When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure.
^ Use a new gasket.
33) Install the water by-pass pipe for heater.
Tightening torque:
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
34) Install the oil filter.
35) Install the cylinder head.
36) Install the generator and A/C compressor with their brackets.
Tightening torque:
36 N.m (3.7 kgf-m, 26.6 ft-lb)
37) Install the crank sprocket.
38) Install the timing belt.
39) Adjust the valve clearance.
40) Install the rocker cover.
1) Install the rocker cover gasket to the rocker cover.
NOTE:
Use a new rocker cover gasket.
2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages.
Tightening torque:
1st
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Second (only (a) and (b) are tightened)
6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
RH side
LH side
41) Install the timing belt cover.
42) Install the crank pulley.
43) Install the intake manifold.
44) Install the V-belts.