Reassembly
Part 1 Of 2:
Part 2 Of 2:
REASSEMBLY
HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply fresh 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) Gradually heat the piston side of connecting rod to 80 - 90°C (176 - 194°F).
b) Coat the piston pin and pin holes of the piston with engine oil.
c) Align the cavity on the piston with the protrusion on the connecting rod.
d) Using SST, press in the piston pin.
SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150)
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.
c) Position the Piston rings so that the ring ends are as shown.
NOTICE: Do not align the ring ends.
3. Supply parts: INSTALL MAIN BEARINGS
HINT: 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.
NOTICE: Install the bearing with the oil hole in the cylinder block.
b) Align the bearing claw with the claw grove of the main bearing cap, and push in the 5 lower bearings.
4. Manufacture parts:
INSTALL MAIN BEARINGS
HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not.
Measure the clearance on both sides of the bearing and install it so that the difference between measured values will be within the specified below.
Specified clearance:
A - B = 0.8 mm (0.032 inch)
C - D = 0.4 mm (0.016 inch)
5. PLACE CRANKSHAFT ON CYLINDER BLOCK
6. INSTALL BEARING CAPS
a) Install the 5 bearing caps.
HINT: Each bearing cap has a number and front mark.
b) Apply a light coat of engine oil on the threads and under the head of the bearing cap bolts.
c) Install and uniformly tighten the 10 bolts of the bearing cap is several passes, in the sequence shown.
Torque:
1ST 22 Nm (220 kgf-cm, 16 ft. lbs.)
2ND Turn 90°
d) Check that the crankshaft turns smoothly.
7. CHECK CRANKSHAFT THRUST CLEARANCE
8. INSTALL PISTON AND CONNECTING ROD ASSEMBLES
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.
9. PLACE CONNECTING ROD CAP ON CONNECTING ROD
a) Match the numbered connecting rod cap with the connecting rod.
b) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
c) Check that the protrusion of the connecting rod cap is facing in the correct direction.
10. INSTALL CONNECTING ROD CAP BOLTS
HINT:
^ The connecting rod cap bolts are tightened in 2 progressive steps (steps b) and (d)).
^ If any of the connecting rod cap bolts is broken or de formed, replace it.
a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
b) Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque:
1ST 15 Nm (150 kgf-cm, 11 ft. lbs.)
2ND Turn 90°
If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
11. CHECK CONNECTING ROD THRUST CLEARANCE
12. INSTALL OIL PAN NO. 1
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan No. I and cylinder block.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
^ 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 oil pan No. 1 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 3 minutes of application. Otherwise the material must be removed and and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
c) Install new O-rings to the cylinder block.
d) Using a plastic-faced hammer, lightly tap the oil pan No. 1 to ensure a proper fit.
e) Install and uniformly tighten the 13 bolts, in several passes, in the sequence shown.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
HINT: Each bolt length in indicated in the illustration.
A: 49 mm (1.929 inch)
B: 88 mm (3.465 inch)
C: 144 mm (5.669 inch)
13. INSTALL REAR CRANKSHAFT OIL SEAL
HINT: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
14. INSTALL OIL STRAINER
Install a new gasket, and oil strainer with the 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8 ft. lbs.)
15. INSTALL OIL PAN
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.
NOTICE: Do not use a solvent which will affect the painted surfaces.
b) Apply seal packing to the oil pan as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
^ Install a nozzle that has been cut to a 2.5 - 3.5 mm (0.098 - 0.138 inch) opening.
HINT: Avoid applying an excessive amount to the surface.
^ Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
c) Install the oil pan with the 9 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
16. INSTALL OIL FILTER UNION
Torque: 30 Nm (306 kgf-cm, 21 ft. lbs.)
17. INSTALL OIL FILTER
18. INSTALL ENGINE COOLANT DRAIN UNION
a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
b) Install the drain union.
Torque: 35 Nm (350 kgf-cm, 25 ft. lbs.)
HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
19. INSTALL KNOCK SENSOR
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
20. INSTALL OIL PRESSURE SWITCH
21. INSTALL THERMOSTAT
22. INSTALL WATER BYPASS PIPE
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.
23. INSTALL ENGINE WIRE
24. INSTALL CYLINDER HEAD
25. INSTALL TIMING SPROCKETS AND TIMING CHAIN
26. REMOVE ENGINE STAND
27. M/T:
INSTALL FLYWHEEL
HINT: The flywheel bolts are tightened in 2 progressive steps, (a) and (c).
a) Install and uniformly tighten the 6 mounting bolts, in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Mark the flywheel bolt with paint.
c) Retighten the flywheel bolts by an additional 90°.
d) Check that the painted mark in now at a 90° angle to (b).
28. A/T
INSTALL DRIVE PLATE
a) Install the front spacer, drive plate and rear plate on the crankshaft.
b) Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent
c) Install and uniformly tighten the 6 mounting bolts, in several passes, in the sequence shown.
Torque: 88 Nm (890 kgf-cm, 65 ft. lbs.)