Part 1

ENGINE UNIT

COMPONENTS:

REASSEMBLY (STEPS 1-27)

1. INSTALL RING PIN
a. Using a plastic-faced hammer, tap into the ring pin.
2. INSTALL TIGHT PLUG
a. Apply adhesive around the tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.

b. Using SST, install new tight plugs as shown in the illustration.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07100)

3. INSTALL STUD BOLT
a. Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Stud bolt B 10 Nm (102 kgf-cm, 7 ft. lbs.)
Stud bolt C 5.0 Nm (51 kgf-cm, 44 inch lbs.)
4. INSTALL STRAIGHT PIN

a. Using a plastic-faced hammer, tap into the straight pin.

5. INSTALL PISTON
a. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
b. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

c. Align the front marks of the piston and connecting rod, and push in the piston with your thumb.
d. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

6. INSTALL PISTON RING SET
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 painted mark as shown in the illustration.

NOTICE: Install the compression ring No. 2 with the code mark (2N) facing upward.

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

7. INSTALL CRANKSHAFT BEARING
a. Install the upper bearing with an oil groove on the cylinder block.

NOTICE: Clean the contact surfaces of the bearing and the cylinder block. The surfaces should be free of dust and oils.

8. INSTALL CRANKSHAFT BEARING NO. 2
a. Install the lower bearing on bearing cap.

NOTICE: Clean the contact surfaces of the bearing and the bearing cap. The surfaces should be free of dust and oils.

9. INSTALL CRANKSHAFT THRUST WASHER UPPER
a. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
10. INSTALL CRANKSHAFT
a. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
b. Examine the front marks and numbers and install the bearing caps on the cylinder block.
c. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts.

d. Install and uniformly tighten 10 main bearing cap bolts in several passes, in the sequence shown.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)

e. Mark the front side of the bearing cap bolts with paint.
f. Retighten the bearing cap bolts 90° in the sequence shown.
g. Check that the painted mark is now at a 90° angle to the front.
h. Check that the crankshaft turns smoothly.

11. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the groove of the connecting rod or connecting cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oil.

12. INSTALL PISTON

NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps.

a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
b. Check the position of the piston ring ends.

c. 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.

NOTICE: Match the numbered connecting rod cap with the connecting rod.

d. Check that the protrusion of the connecting rod cap is facing in the correct direction.
e. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
f. Using a 12 mm socket wrench, uniformly tighten the 2 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
g. Mark the front of the connecting cap bolts with paint.

h. Retighten the cap bolts 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.
13. INSTALL BALANCE SHAFT BEARING NO. 1
a. Install the bearings in the crankcase and balance shaft housing.
b. Apply a light coat of engine oil on the bearings.

14. INSTALL BALANCE SHAFT NO. 1 AND NO. 2
a. Rotate the driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper.
b. Confirm that the matchmarks on driven gear No. 1 and No. 2 are matched.

c. Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.
d. Place the No. 1 and No. 2 balance shafts on the crank case.
e. Apply a light coat of engine oil under the heads of the balance shaft housing bolts.

f. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)

HINT: The balance shaft housing bolts are tightened in 2 progressive steps.

g. Mark the front side of each balance shaft housing bolt head with paint.
h. Retighten the bolts by 90° as shown in the illustration.
i. Check that the painted marks are now at a 90° angle to the front.

15. INSTALL STIFFENING CRANKCASE ASSEMBLY
a. Apply seal packing in a continuous bead (seal width: 2.5 to 3.0 mm (0.098 to 0.118 inch)) to the places shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

b. Place a new O-ring on the cylinder block, as shown in the illustration.

c. With the No. 1 crank pin of the crankshaft placed at 6 o'clock, install the No. 1 and No. 2 balance shaft and the adjusting hole as shown in the illustration.

d. Uniformly tighten the 11 bolts in the sequence shown in the illustration.
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)

e. Confirm that the timing marks of the balance shafts are matched when the key groove is placed at 6 o'clock, as shown in the illustration.

16. INSTALL ENGINE REAR OIL SEAL
a. Apply MP grease to a new oil seal lip.

NOTICE: Keep the lip off the foreign materials.

b. Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE: Wipe off extra grease on the crankshaft.

17. INSTALL W/HEAD TAPER SCREW PLUG NO. 1
a. Apply adhesive to the threads of the plug and install it.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

18. INSTALL OIL CONTROL VALVE FILTER FOR CAMSHAFT TIMING
a. Check that no foreign substance is on the mesh part of the filter.
b. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

19. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Install the water drain cock within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

20. INSTALL CYLINDER HEAD GASKET
a. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
^ Remove any oil from contact surface.
^ Be careful of the installation direction.
^ To avoid damage to the gasket, place the cylinder head on the gasket carefully.

21. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT: The cylinder head bolts are tightened in 2 progressive steps.

a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the 10 bolts and plate washers to the cylinder head.

NOTICE: Do not drop the washers into the cylinder head.

c. Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)

d. Mark the front side of each cylinder head bolt with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
f. Check that the painted marks are now at a 90° angle to the front.
22. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

23. INSTALL CAMSHAFT BEARING NO. 2
a. Install the bearing to the camshaft.

NOTICE: Clean the contact surfaces of the bearing and the cylinder head. the surfaces should be free of dust and oils.

24. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
a. Put the camshaft timing gear and the camshaft together with the straight pin and key groove.
b. Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin enters the groove.

CAUTION: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right angle).

c. Check that there is no clearance between the gear's fringe and the camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
e. Check that the camshaft timing gear can move to the retarded angle side (the right direction) and is locked at the extreme retarded angle position.

HINT:
^ Apply a light coat of engine oil on the threads and under the heads of the bolt.
^ Length of sprocket bolt excluding bolt head: 40 mm (1.57 inch)

25. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Fix the camshaft with a vise, and install the camshaft No. 2 timing gear.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

HINT:
^ Apply a light coat of engine oil on the threads and under the heads of the bolt.
^ Length of sprocket bolt excluding bolt head: 25 mm (0.98 inch)

26. INSTALL CAMSHAFT BEARING NO. 1

27. INSTALL CAMSHAFT
a. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 Nm (306 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Tighten the bolts after deciding the position for the thrust direction of the camshaft by the bearing cap No. 1.
^ Install the camshaft with its timing mark of the camshaft timing gear on top.