Assembly

ASSEMBLY OF PISTON AND CONNECTING ROD
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 approx. 60°C (140°F).

(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and the connecting rod, and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the pin hole.

2. INSTALL PISTON RINGS
(a) Install the oil ring expander and two side rails by hand.

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

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

NOTICE: Install the bearings with the oil hole in the connecting rod.

ASSEMBLY OF CYLINDER BLOCK

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. (7M-GTE) INSTALL OIL NOZZLES
Torque: 25 N.m (250 kgf.cm 18 ft.lbf)

2. INSTALL MAIN BEARINGS

HINT Different bearings are used for the No.1 and others.

(a) Align the bearing claw with the claw groove of the main bearing cap or cylinder block.
(b) Install the bearing in the cylinder block and bearing caps.

NOTICE: Install the bearing with the oil hole in the block.

3. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.4 main journal position of the block with the oil grooves facing outward.
4. PLACE CRANKSHAFT ON CYLINDER BLOCK

5. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS

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

(a) Install the thrust washers on the No.4 bearing cap with the grooves facing outward.

(b) Install the bearing caps in numbered order with arrows facing forward.
(c) Install and uniformly tighten the fourteen cap bolts in several passes, in the sequence shown.
Torque: 102 N.m (1,040 kgf.cm, 75 ft.lbf).
(d) Check that the crankshaft turns smoothly.
(e) Check the crankshaft thrust clearance. (See step 21 above)

6. 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.

7. INSTALL CONNECTING ROD CAPS
(a) Match the numbered cap with the numbered connecting rod.
(b) Install the cap with the protrusion facing forward.

(d) Install and alternately tighten the cap nuts in several passes.
torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance. (See step 18 above)

8. INSTALL OIL PUMP ASSEMBLY
(a) Clean the oil pump.
(b) Install the oil pump with the two bolts and union nut.
Torque:
Bolt (A) 22 N.m (220 kgf.cm, 16 ft.lbf)
Bolt (B) 5.9 N.m (60 kgf.cm, 52 in.lbf)
Union nut 34 N.m (350 kgf.cm, 25 ft.lbf)

9. INSTALL OIL PUMP DRIVE SHAFT
(a) While turning the drive shaft, insert slowly to avoid damaging the drive shaft bearing.

(b) Install the bolt.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

10. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and rear oil seal retainer with the five bolts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

11. IN STALL TIMING BELT CASE WITH WATER PUMP
(a) Position new gaskets on the cylinder block.
(b) Apply sealant to two or three threads of the 10 mm bolt end.
Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent.
(c) Install the timing belt case with the seven bolts and three nuts.
Torque:
12 mm head bolt and nut 19 N.m (195 kgf.cm, 14 ft.lbf)
14 mm head bolt 39 N.m (400 kgf.cm, 29 ft.lbf)
12. INSTALL OIL PAN Oil Pan

13. INSTALL PS PUMP BRACKET
14. INSTALL OIL HOLE COVER PLATE
Install a new gasket and oil hole cover plate with the two bolts.
15. (7M-GE) INSTALL NEW OIL FILTER
16. INSTALL ENGINE MOUNTING BRACKETS

17. INSTALL FUEL RETURN PIPE SUPPORT
Install a new insulator and fuel pipe support with the two nuts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
18. (7M-GE) INSTALL VACUUM CONTROL VALVE SET
19. INSTALL GROUND STRAP TO CYLINDER BLOCK

20. INSTALL WATER BY-PASS PIPE
(a) Install a new gasket and water by-pass pipe to the timing belt case with the two nuts.
Torque: 14 N.m (140 kgf.cm, 10 ft.lbf).
(b) Install the water by-pass pipe to the cylinder block with the three bolts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

21. INSTALL CYLINDER HEAD

1987-92 Model

(a) Apply seal packing to the two locations shown. Seal packing: Part No.08826-00080 or equivalent

(b) Place a new cylinder head gasket on the cylinder block.

NOTICE: Be sure to install the gasket correctly.

(c) Place the cylinder head on the cylinder head gasket, and connect the No.5 water by-pass hose to the union.
(d) Apply a light coat of the engine oil on the threads and under the cylinder head bolts.
(e) Using SST, install and uniformly tighten the fourteen cylinder head bolts in several passes, in the sequence shown. SST 09043-38100
Torque: 78 N.m (800 kgf.cm, 58 ft.lbf)
2. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING BELT Timing Components
3. INSTALL SPARK PLUGS

4. INSTALL CYLINDER HEAD COVERS
(a) Using SST, install the No.3 cylinder head cover. SST 0992300010
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)

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

(c) Install the No.1 and No.2 cylinder head covers.
Torque: 2.5 N.m (25 kgf.cm, 22 in. lbf)
(d) Install the heater hose clamp.
(e) Install the accelerator linkage.

5. INSTALL WATER OUTLET HOUSING
(a) Install a new gasket and water outlet housing with the bolt and two nuts.
(b) Connect the No.6 water by-pass hose.

6. INSTALL EXHAUST MANIFOLD
(a) Face a new exhaust gasket so the protrusion is facing the rear and install on the cylinder head.

(b) Install the exhaust manifold with the seven nuts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

(d) (7M-GTE)
Install the heat insulators with the five bolts.
7. (7M-GTE)
INSTALL TURBOCHARGER
8. (7M-GE)
INSTALL OIL DIPSTICK
9. (7M-GE)
INSTALL DISTRIBUTOR AND HIGH-TENSION CORDS

10. (7M-GTE)
INSTALL AUXILIARY AIR PIPE

11. INSTALL NO.2 FUEL PIPE
(a) Install a new gasket, No.2 fuel pipe, another gasket and union bolt to the pressure regulator.
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
(b) Install the No.2 fuel pipe to the delivery pipe with the bolt.
(c) Connect the fuel hose to fuel return pipe support.

12. INSTALL NO.1 FUEL PIPE
(a) Install the No.1 fuel pipe with VSV with the clamp bolt.
(b) Connect the pipe to the fuel pipe support with the union bolt and new gaskets. Torque the union bolt.
Torque: 31 N.m (320 kgf.cm 23 ft.lbf
(c) Connect the pipe to the delivery pipe with the union bolt (7M-GE) or pulsation damper (7M-GTE) and new gaskets. Torque the union bolt or pulsation damper.
Torque:
Union bolt 31 N.m (320 kgf.cm, 23 ft.lbf)
Pulsation damper 26 N.m (270 kgf.cm, 20 ft.lbf)
13. INSTALL ENGINE WIRE
(a) Install the engine wire to the four clamps.
(b) Connect the following connectors and wire:
- Transmission connectors
- Starter connector (Terminal 50)
- Main relay connector
- Noise filter connector
- (7M-GE)
Ignition coil connector
- (7M-GTE)
Igniter connectors
- (7M-GTE)
Solenoid resistor connector
- Check connector
- Ground strap to intake manifold
- Knock sensor connector
- Two VSV connectors
- Injector connectors
- (7M-GE)
Distributor connector
- Cold start injector time switch connector
- Water temp. sender gauge connector
- Water temp. sensor connector
- Oil pressure sender gauge connector
- Oxygen sensor connector
14. (7M-GTE)
INSTALL IGNITION COIL WITH BRACKET
15. INSTALL AIR INTAKE CHAMBER WITH CONNECTOR
(a) Position a new gasket on the intake manifold.
(b) (7M-GTE)
Connect the cold start injector connector.

(c) Install the intake chamber with connector and vacuum lines with the two nuts and five bolts.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
(d) Connect the engine wire to the clamps of the intake chamber.

(e) Install new gaskets and cold start injector tube.
Torque:
To delivery pipe 31 N.m (320 kgf.cm, 23 ft.lbf)
To cold start injector 11 N.m (115 kgf.cm. 8 ft.lbf)
(f) Install the EGR vacuum modulator to the bracket.

(g) (7M-GE)
Install the air intake connector bracket mounting bolts.

(h) (7M-GE)
Install the throttle body brackets

(i) (7M-GTE
Install the ISC pipe and connect the hoses.

(j) Install the EGR pipe mounting bolts.
(k) Install the manifold stay mounting bolt.
(I) Connect the following hoses:
- (7M-GE)
No.3 water by-pass hose to throttle body
- (7M-GTE)
No.3 water by-pass hose to water by-pass pipe
- No.1 water by-pass hose to union of cylinder block
- (7M-GTE)
Auxiliary air pipe hose to vacuum line
- (7M-GE)
Diaphragm hose
- (7M-GTE)
VSV hoses (for FPU)
- PS air hose
- Pressure regulator hose
- Vacuum line to intake chamber
- EGR hoses to throttle body and vacuum transmitting pipe.
- BVSV hose to throttle body
(m) Connect the following wires:
- ISC valve connector
- Throttle position sensor connector
- (7M-GE)
Cold start injector connector
(n) Install the PCV pipe.
16. (7M-GTE)

17. (7M-GTE)
INSTALL PS RESERVOIR TANK
Install the PS reservoir tank with bracket.
18. INSTALL ALTERNATOR AND ADJUSTING BAR
(a) Install the alternator and adjusting bar.
(b) Install the drive belt.
(c) Connect the No.3 PCV pipe.

INSTALL CAM POSITION SENSOR 22. INSTALL TIMING BELT Timing Components
23. REMOVE ENGINE STAND
24. INSTALL REAR END PLATE
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

25. INSTALL FLYWHEEL OR DRIVE PLATE ON CRANKSHAFT
(a) Install the flywheel or drive plate on crankshaft
(b) Apply a light coat of engine oil on the threads and under the bolt heads.
(c) Install and uniformly tighten the bolts in several passes, in the sequence shown.
Torque: 74 N.m (750 kgf.cm, 54 ft.lbf)