Assembly

NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.

1. Install oil nozzles and check valves.

Install the oil nozzle with the check valve. Install the 4 oil nozzles and 4 check valves.
Torque: 25 Nm (250 kg.cm, 18 ft. lbs.)
2. Install main bearings.

NOTE:
- Main bearings come in widths of 23 mm (0.91 inch) and 25 (0.98 inch). Install the 23 mm (0.91 inch) bearings in the No. 2, No. 3 and No. 4 cylinder block journal positions with the main bearing caps. Install the 25 mm (0.98 inch) bearings in the No. 1 and No. 5 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.

CAUTION: Install the bearing with the oil hole in the cylinder block.

(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

NOTE: A number is marked on each main bearing cap to indicate the illustration 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. Place Main Bearing Cap And Lower Thrust Washers On Cylinder Block.

(a) Install the 2 thrust washers on the No. 3 bearing cap with the oil grooves facing outward.

(b) Install the 5 main bearing caps in their proper locations.

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

B. Install Main Bearing Cap Bolts.

NOTE:
- The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
- If any one of the main bearing cap bolts is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.

(b) Install and uniformly tighten the 10 the main bearing cap bolts, in several passes, in the sequence shown.
Torque: 39 Nm (400 kg.cm, 29 ft. lbs.)
If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

(d) Retighten the main bearing cap bolts by 90° in the numerical order shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance. Disassembly
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 2° - 3° to the right of the central axis as shown in the illustration.

CAUTION: Install the connecting rod so that it does not touch the oil nozzle.

7. Install connecting rod caps.

A. Place Connecting Rod Cap On Connecting Rod.
(a) Match the numbered connecting rod cap with the connecting rod.

(b) Install the connecting rod cap with the front mark facing forward.

B. Install Connecting Rod Cap Nuts.

NOTE:
- The connecting rod cap nuts are tightened in 2 progressive steps (steps (b) and (d)).
- If any connecting rod bolt is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap.

(b) Install and alternately tighten the nuts of the connecting rod cap in several passes.
Torque: 45 Nm (460 kg.cm, 33 ft. lbs.)
If any of the connecting rod cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set.

(d) Retighten the cap bolts by 90° as shown.

(e) Check that the painted mark on the nut is at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance. Disassembly
8. Install rear oil seal retainer.
(a) Remove any old packing, Formed In Place Gasket (FIPG), material and be careful not to drop any oil on the contact surfaces of the rear oil seal retainer and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- 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 rear oil seal retainer as shown in the illustration.
Seal packing: Part No. 0882B-00080 or equivalent.
- Install a nozzle that has been cut to a 2 mm (0.08 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
(c) Install the oil seal retainer with the 6 bolts.
Torque: 13.5 Nm (135 kg.cm, 10 ft. lbs.)