Assembly

REASSEMBLY

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.

1. ASSEMBLE PISTON AND CONNECTING ROD





a. Install a new snap ring on one side of the piston pin hole.
b. Gradually heat the piston to at 80 - 90°C (176 - 194°F).
c. Coat the piston pin with engine oil.





d. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.





e. Install a new snap ring on the other side of the piston pin hole.
2. INSTALL PISTON RINGS
a. Install the oil ring expander and 2 side rails by hand.





b. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

Code mark:
"1T" or "1N" for No.1
"2T" or "2N" for No.2





c. Position the piston rings so that the ring ends are as shown.

NOTICE: Do not align the ring ends.

3. INSTALL BEARINGS
a. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
b. Install the bearings in the connecting rod and connecting rod cap.





4. INSTALL CYLINDER BLOCK ORIFICE





5. INSTALL NO.1 AND NO.2 BALANCE SHAFTS
a. No.1 balance shaft (RH): Has indentations.
b. No.2 balance shaft (LH): Has no indentations.
6. ASSEMBLY NO.1 BALANCE SHAFT
a. Mount the hexagon wrench head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.





b. Install these parts to the balance shaft:
1) No. 1 balance shaft
2) No.1 balance shaft thrust plate
3) Balance shaft thrust spacer
4) Balance shaft timing gear
5) Key
c. Install and torque the bolt.

Torque: 36 Nm (26 ft. lbs.)

7. ASSEMBLY NO.2 BALANCE SHAFT
a. Mount the hexagon wrench head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.





b. Install these parts to the balance shaft:
1) No.2 balance shaft
2) No.2 balance shaft thrust plate
3) Balance shaft timing sprocket
c. Install and torque the bolt.

Torque: 36 Nm (26 ft. lbs.)





8. INSTALL BALANCE SHAFTS
a. Install balance shafts.

NOTICE: When installing the balance shaft make sure you support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.





b. Install the No.1 balance shaft with the bolt.
c. Install the No.2 balance shaft with the 2 bolts.

Torque: 18 Nm (13.4 ft. lbs.)





9. INSTALL MAIN BEARINGS
a. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.





b. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.





HINT: A number is marked on each main bearing cap to indicate the installation position.





10. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.
11. PLACE CRANKSHAFT ON CYLINDER BLOCK





12. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK
a. Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.





b. Install the 5 main bearing caps in their proper locations.

HINT: Each bearing cap has a number and front mark.

13. INSTALL MAIN BEARING CAP BOLTS

HINT:
- The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
- If any of the main bearing cap bolts is broken or deformed, replace it.

a. Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.





b. Install and uniformly tighten the 10 bolts of the main bearing caps, in several passes, in the sequence shown.

Torque: 39 Nm (29 ft. lbs.)

If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
c. Mark the front of the main bearing cap bolt with paint.





d. Retighten the main bearing cap bolts by 90° in the numerical order shown above.
e. Check that the painted mark is now at a 90° angle to the front.
f. Check that the crankshaft turns smoothly.
g. Check the crankshaft thrust clearance.





14. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES
a. Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.





b. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
15. PLACE CONNECTING ROD CAP ON CONNECTING ROD
a. Match the numbered connecting rod cap with the connecting rod.





b. Install the connecting rod cap with the front mark facing forward.
16. INSTALL CONNECTING ROD CAP NUTS

HINT:
- The connecting rod cap nuts are tightened in 2 progressive steps (steps (b) and (d)).
- If any connecting rod bolt is broken or deformed, replace it.

a. Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap.





b. Install and alternately tighten the nuts of the connecting rod cap in several passes.

Torque: 45 Nm (33 ft. lbs.)

If any one of the connecting rod cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set.
c. Mark the front of the connecting rod cap nut and bolt with paint.





d. Retighten the connecting rod cap nuts 90° as shown.
e. Check that the painted mark on the nut is at a 90° angle in relation to the mark on the bolt.
f. Check that the crankshaft turns smoothly.
g. Check the connecting rod thrust clearance.
17. INSTALL REAR OIL SEAL RETAINER
a. Remove any old packing Formed In Place Gasket (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.





b. Apply seal packing to the retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.

c. Install the retainer with the 6 bolts.

Torque: 13.5 Nm (9.7 ft. lbs.)

18. INSTALL LH ENGINE MOUNTING BRACKET





Install the bracket with the 5 bolts.

Torque:
Bolt A: 51 Nm (34 ft. lbs.)
Bolt B: 20 Nm (14 ft. lbs.)

19. INSTALL RH ENGINE MOUNTING BRACKET
Install the bracket with the 4 bolts.

Torque: 51 Nm (34 ft. lbs.)

20. INSTALL OIL PRESSURE SWITCH





a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





b. Using Special Service Tools (SST), install the oil pressure switch.
SST 09816 - 30010
21. INSTALL ENGINE COOLANT DRAIN PLUG
a. Apply adhesive to 2 or 3 threads of the engine coolant drain plug.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the engine coolant drain plug.

Torque: 25 Nm (18 ft. lbs.)

22. INSTALL OIL FILTER BRACKET UNION
a. Install a new O-ring.
b. Using 14 mm hexagon wrench, install the oil filter bracket union.

Torque: 25 Nm (18 ft. lbs.)

23. INSTALL OIL FILTER AND BRACKET
a. Install a new O-ring and oil filter bracket with the 2 bolts and nut.

Torque: 28 Nm (21 ft. lbs.)

b. Install the oil filter.
24. INSTALL WATER BYPASS PIPE
Install the bolt and water bypass pipe.

Torque: 20 Nm (14 ft. lbs.)

25. INSTALL KNOCK SENSOR





Using SST, install the knock sensor.
SST 09816 - 30010

Torque: 37 Nm (27 ft. lbs.)

26. INSTALL FUEL FILTER
Install the 2 bolts and fuel filter.

Torque: 20 Nm (14 ft. lbs.)

27. INSTALL TIMING CHAINS, GEARS AND SPROCKETS
28. INSTALL CYLINDER HEAD
29. REMOVE ENGINE STAND





30. INSTALL REAR END PLATE
Install the rear end plate with the 3 bolts.

Torque:
Bolt A: 18 Nm (13 ft. lbs.)
Bolt B: 20 Nm (14 ft. lbs.)

31. M/T: INSTALL FLYWHEEL





a. Install and uniformly tighten 10 new bolts to the flywheel, in several passes, in the sequence shown.

Torque: 26.5 Nm (19 ft. lbs.)

b. Mark the top of the flywheel bolt with paint.





c. Retighten the flywheel bolts by 90° in the numerical order shown above.
d. Check that the painted mark is now at a 90° angle to the top.
A/T: INSTALL DRIVE PLATE
Install the front spacer, drive plate and rear spacer with the 10 bolts.

Torque: 74 Nm (56 ft. lbs.)