Assembly
PISTON INSTALLATION1. Apply a coat of engine oil to the ring grooves and cylinder bores.
If the crankshaft is already installed:
2. Set the crankshaft to BDC for each cylinder.
3. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
4. Install the ring compressor, and check that the bearing is securely in place.
5. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer. Maintain downward force on the ring compressor to prevent rings from expanding before entering the cylinder bore.
6. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing piston into place.
7. Install the rod caps with bearings, and torque the nuts to:
31 Nm (3.2 kgf.m, 23 ft. lbs.)
Apply engine oil to the bolt threads.
If the crankshaft is not installed:
2. Remove the rod caps and bearings, and install the ring compressor.
3. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer. Maintain downward force on the ring compressor to prevent rings from expanding before entering the cylinder bore.
4. Position all the pistons at the top dead center.
CRANKSHAFT INSTALLATION
1. Apply a coat of engine oil to the main bearings and rod bearings.
2. Insert the bearing halves in the cylinder block and connecting rods.
3. Hold the crankshaft so the rod journals for cylinders No. 2 and No. 3 are straight down.
4. Lower the crankshaft into the block, seating the rod journals into connecting rods No. 2 and No. 3. Install the rod caps and nuts finger-tight.
5. Rotate the crankshaft clockwise, and seat the journals into connecting rods No. 1 and No. 4. Install the rod caps and nuts finger-tight. Install the caps so the bearing recess is on the same side as the recess in the rod.
6. Check the rod bearing clearance with Plastigage, then torque the cap nuts.
Torque:
31 Nm (3.2 kgf.m, 23 ft. lbs.)
Apply engine oil to the bolt threads.
7. Install the thrust washers on the No. 4 journal.
8. Coat the thrust washer surfaces and bolt threads with oil.
9. Install the main bearing caps. Check clearance with Plastigage, then tighten the bearing cap bolts in 2 steps.
First step: 25 Nm (2.5 kgf.m, 18 ft. lbs.)
Second step: 76 Nm (7.8 kgf.m, 56 ft. lbs.)
NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for approximately 15 minutes.
10. Clean and dry the right side cover mating surfaces.
11. Apply liquid gasket part No. 08718-0001 or 08718-0003 evenly to the block mating surface of the right side cover and to the inner threads of the bolt holes. Install it on the cylinder block.
NOTE:
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
12. Apply liquid gasket to the oil pump mating surface of the block.
13. Apply a light coat of oil to the crankshaft, the lip of the seal, and the O-rings.
14. Apply grease to the lips of the oil seals.
15. Install the oil pump while aligning the inner rotor with the crankshaft. When the pump is in place, clean any excess grease off the crankshaft, then check that the oil seal lips are not distorted.
16. Apply liquid gasket on the oil pump and right side cover mating areas.
17. Install the oil pan gasket and oil pan. Wait no more than five minutes after applying liquid gasket.
18. Tighten the bolts and nuts finger tight at six points.
19. Tighten all bolts and nuts, starting from nut (1), clockwise in three steps. Excessive tightening can cause distortion of the oil pan gasket and oil leakage.
Torque: 12 Nm (1.2 kgf.m, 8.7 ft. lbs.)
OIL SEALS INSTALLATION
1. Dry the crankshaft oil seal housing.
2. Apply a light coat of grease to the crankshaft and to the lips of the seals.
3. Using the special tool, drive in the timing pulley-end seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.
4. Measure the flywheel-end seal thickness and the oil seal housing depth. Using the special tool, drive the flywheel-end seal into the rear cover to the point where the clearance between the bottom of the oil seal and the right side cover is 0.5 - 0.8 mm (0.02 - 0.03 inch). Align the hole in the driver attachment with the pin on the crankshaft.