Assembly
CYLINDER BLOCK ASSEMBLY
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, 0-rings and oil seals with new parts.
1. INSTALL OIL NOZZLES
Using a 5 mm hexagon wrench, install the oil nozzle with the bolt. Install the 4 oil nozzles.
Torque: 9.1 N.m (93 kgf.cm. 81 in. lbf)
2. INSTALL MAIN BEARINGS
HINT:
- Main bearings come in widths of 19.2 mm (0.756 in.) and 23.0 mm (0.906 in.). Install the 23.0 mm (0.906 in.) bearings in the No.3 cylinder block journal position with the main bearing cap. Install the 19.2 mm (0.756 in.) 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 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.
3. 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.
4. PLACE CRANKSHAFT ON CYLINDER BLOCK
5. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS
(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.
(c) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.
(d) Install and uniformly tighten the 1 0 bolts of the main bearing cap in several passes. in the sequence shown.
Torque: 59 N.m (600 kgf.cm, 43 ft. lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance.
- Using a dial indicator. measure the thrust clearance while prying the crankshaft back an forth with a screwdriver.
Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
6. INSTALL PISTON AND CONNECTING ROD ASSEMBLES
(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.
7. INSTALL CONNECTING ROD CAPS
(a) Match the numbered connecting rod cap with the connecting rod.
(b) Install the connecting rod cap with the front mark facing forward.
(c) Apply a light of engine oil on the threads and under the nuts of the connecting rod cap.
(d) Install and alternately tighten the 2 cap nuts in several passes.
Torque: 67 N.m (680 kgf.cm, 49 ft. lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 - 0.312 mm (0.0063 - 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
8. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 9.3 N.m (95 kgf.cm, 82 in. lbf)
AFTER ASSEMBLY
1. INSTALL KNOCK SENSOR
Using SST, install the knock sensor. SST 09816-30010
Torque: 37 N.m (380 kgf.cm. 27 ft. lbf)
2. INSTALL OIL COOLER BRACKET AND OIL COOLER (See oil cooler installation in Lubrication System)
3. INSTALL WATER PUMP AND WATER PUMP COVER ASSEMBLY
(a) Install a new 0-ring to the water pump cover.
(b) Install the water pump with the 3 bolts. Tighten the bolts in the sequence shown.
Torque: 7.8 N.m (80 kgf.cm. 69 in. lbf)
(c) w/o A/C:
Install the bolt (A).
Torque: 27 N.m (275 kgf.cm. 20 ft. lbf)
4. INSTALL OIL DIPSTICK GUIDE
(a) Install a new 0-ring to the dipstick guide.
(b) Apply soapy water to the 0-ring.
(c) Insert the dipstick guide into the guide hole of the cylinder block.
(d) Install the dipstick guide with the bolt.
5. INSTALL OIL PUMP AND AND OIL PAN
6. INSTALL CYLINDER HEAD Cylinder Head Assembly
7. INSTALL TIMING BELT AND PULLEYS Timing Belt
8. INSTALL ALTERNATOR BRACKET
Torque: 43 N.m (440 kgf.cm. 32 ft. lbf)
INSTALLATION OF ALTERNATOR
1. INSTALL ALTERNATOR
(a) Mount the alternator on the alternator brackets with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet.
(b) Connect the alternator connector.
(c) Connect the alternator wire with the nut.
2. INSTALL DRIVE BELT
Adjust the drive belt tension.
Drive belt tension:
New belt: 120 ± 20 lbf
Used belt: 104 ± 20 lbf
3. INSTALL RH ENGINE MOUNTING BRACKET
Torque: 61 N.m (620 kgf.cm. 45 ft. lbf)
4. INSTALL OIL LEVEL SENSOR WIRE
(a) Install the sensor wire with the 2 bolts.
(b) Connect the 2 connectors.
5. DISCONNECT ENGINE FROM ENGINE STAND
6. INSTALL REAR END PLATE
Install the rear end plate with the bolt.
Torque: 9.3 N.m (95 kgf.cm. 82 in. lbf)
7. INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No.08833-00070. THREE BOND 1324 or equivalent
(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the 6 bolts in several passes, in the sequence shown.
Torque: 108 N.m (1,100 kgf.cm. 80 ft. lbf)
ENGINE AND TRANSAXLE ASSEMBLY
1. INSTALL CLUTCH DISC AND COVER
2. INSTALL TRANSAXLE TO ENGINE
(a) Attach the transaxle to the engine.
(b) Install the 5 bolts together with these parts:
(1) Ground strap
(2) Engine wire bracket
Torque:
14 mm head: 46 N.m (470 kgf.cm, 34 ft. lbf)
17 mm head: 64 N.m (650 kgf.cm, 47 ft. lbf)
3. INSTALL HEATER WATER PIPE
(a) Install the water pipe with the 2 bolts.
(b) Connect the water hose to the water bypass pipe.
Torque: 46 N.m (470 kgf.cm. 34 ft. lbf)
4. INSTALL NO.2 REAR END PLATE
Install the rear end plate with the 4 bolts.
Torque:
10 mm head: 9.3 N.m (95 kgf.cm, 82 in. lbf)
2 mm head: 19 N.m (195 kgf.cm. 14 ft. lbf)
5. INSTALL STIFFENER PLATE
Torque: 37 N.m (380 kgf.cm, 27 ft. lbf
6. INSTALL STARTER
Torque: 39 N.m (400 kgf.cm, 29 ft. lbf)
7. CONNECT ENGINE WIRE
(a) Connect these parts:
(1) Starter wire
(2) Starter connector
(3) VSS connector
(4) Back-up light switch connector
(5) Engine wire clamp
(6) Engine wire bracket
(b) Install the terminal cover to the starter.