Part 1

ENGINE UNIT

REASSEMBLY

1. INSTALL STUD BOLT

2. INSTALL STRAIGHT PIN

3. INSTALL RING PIN

4. INSTALL WITH PIN PISTON SUB-ASSEMBLY
a. Using a small screwdriver, install anew snap ring on one side of the piston pin hole.

b. Gradually heat the piston to about 60°C (140°F).

c. Coat the piston pin with engine oil.
d. The piston's front mark and the connecting rod's outside mark should face the same direction, as shown in the illustration.

NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with 3L and the RH piston is marked with 3R.

e. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.

f. Check the fit between the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin.

g. Using a small screwdriver, install anew snap ring on the other side of the piston pin hole.

h. Install the oil ring expander and 2 side rails by hand.
i. Using a piston ring expander, install the No.1 and No.2 piston rings with the code mark facing upward.

Code Mark:

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

NOTICE: Do not align the ring ends.

5. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the groove of the connecting rod or connecting cap.
b. Install the bearings in the connecting rod and connecting rod cap.

6. INSTALL CRANKSHAFT BEARING

HINT:
^ Main bearings come in widths of 19.5 mm (0.768 inch) and 22.5 mm (0.886 inch). Install the 22.5 mm (0.886 inch) bearings in the No.1 and No.5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 inch) bearings in the other positions.
^ Upper bearings have an oil groove and oil holes; lower bearings do not.

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 crankshaft bearing cap, and push in the 5 lower bearings.

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

7. INSTALL CRANKSHAFT THRUST WASHER SET
a. Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.

b. Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.

8. INSTALL CRANKSHAFT
a. Place the crankshaft on the cylinder block.

b. Install the 5 crankshaft bearing cap in their proper locations.

HINT: Place the bearing caps level and let them return to their original positions by their own weight.

NOTICE: Do not install the bearing cap by tapping it.

c. Install the crankshaft bearing cap bolts.

HINT:
If any one of the bearing cap bolts is broken or deformed, replace it.

1 Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
2 Install and uniformly tighten the 20 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.
If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.

(3) Mark the front of the crankshaft bearing cap bolt's head with paint.
(4) Retighten the crankshaft bearing cap bolts by 90° as shown in the illustration.
(5) Check that the painted mark is now at a 90° angle to the front.

(6) Install a new seal washer to the crankshaft bearing cap bolt.
(7) Install and uniformly tighten the 10 crankshaft bearing cap bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
d. Check that the crankshaft turns smoothly
e. Check the crankshaft thrust clearance.

9. INSTALL PISTON AND CONNECTING ROD
a. 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: The shape of the piston varies for the LH and RH banks. The LH piston is marked with 3L and the RH piston is marked with 3R.

b. Place the connecting rod cap on the connecting rod.
(1) Match the numbered connecting rod cap with the connecting rod.
(2) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.

(3) Check that the outside mark of the connecting rod cap is facing in correct direction.

c. Install the connecting rod cap bolts.

HINT: If any one of the connecting rod cap bolts is broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(2) Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
If any of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.

(3) Mark the front of the connecting cap bolt with paint.
(4) Retighten the cap bolts 90° as shown in the illustration.
(5) Check that the painted mark is now at a 90° angle to the front.
d. Check that the crankshaft turns smoothly
e. Check the connecting rod thrust clearance.

10. INSTALL WATER SEAL PLATE
a. Remove any old packing (FIPG) material.

b. Apply seal packing to the seal plate as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 2 to 3 mm (0.08 to 0.12 inch)

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

c. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.
Torque: 14 Nm (142 kgf-cm, 10 ft. lbs.)

11. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply seal packing to 2 or 3 threads.
Seal packing: Part No.08826-00100 or equivalent

b. Install the RH and LH drain cocks.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

12. INSTALL CAMSHAFT SETTING OIL SEAL
a. Place a new oil seal into the timing tube.

NOTICE: Be careful of the installation direction.

13. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
a. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
b. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

NOTICE: Be careful not to damage the timing tube.

c. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.

d. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
e. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)
f. Install the seal washer and screw plug.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)

14. INSTALL CAMSHAFT SUB GEAR
a. Install the bolt washer (1), sub gear
(2) and wave washer (3).

HINT: Attach the pins on the gears to the gear bolt washer ends.

b. Using snap ring pliers, install the snap ring.

c. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.

d. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
e. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

15. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any oil packing (FIPG) material.

b. Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 3 to 4 mm (0.12 to 0.16 inch)

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

c. Install a new O-ring to the cylinder block.
d. Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

16. INSTALL OIL PUMP ASSEMBLY
17. INSTALL OIL STRAINER SUB-ASSEMBLY

18. INSTALL OIL PAN STUD BOLT
19. INSTALL OIL PAN SUB-ASSEMBLY
20. INSTALL OIL PAN BAFFLE PLATE
21. INSTALL NO.2 OIL PAN SUB-ASSEMBLY

22. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt 18 Nm (184 kgf-cm, 13 ft. lbs.) for stud bolt and nut

HINT: Use the bolts that are 30 mm (1.18 inch) in length.

RH Bank:

23. INSTALL CYLINDER HEAD SUB-ASSEMBLY
a. Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A 3R mark is on the RH bank's gasket.

NOTICE: Be careful of the installation direction.

b. Place the cylinder head on the cylinder head gasket.

RH Bank:

c. Install the cylinder head bolts.

HINT: If any cylinder head bolt is broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install the place washer to the cylinder head bolt.

RH Bank:

(3) Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.
Torque: 59 Nm (602 kgf-cm, 44 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTICE: Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

RH Bank:

(4) Mark the front of the cylinder head bolt's head with paint.
(5) Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
(6) Check that the painted mark is now at a 90° angle to the front.

LH Bank:

24. INSTALL CYLINDER HEAD LH
a. Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A 3L mark is on the LH bank's gasket.

NOTICE: Be careful of the installation direction.

b. Place the cylinder head on the cylinder head gasket.