Assembly

REASSEMBLY

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, O-rings and oil seals with new parts.

1. ASSEMBLE PISTON AND CONNECTING ROD





a. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.





b. Gradually heat the piston to 80 - 90°C (176 - 194°F).
c. Coat the piston pin with engine oil.





d. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.





e. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
2. INSTALL PISTON RINGS
a. Install the oil ring expander and 2 side rails by hand.





b. Using a piston ring expander, install the No.2 and No.1 piston rings with the code mark facing upward.





Code mark:





c. Position the piston rings so that the ring ends are as shown.

NOTICE: Do not align the ring ends.





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





HINT:
^ Main bearings come in widths of 19.2 mm (0.756 inch) and 22.9 mm (0.902 inch). Install the 22.9 mm (0.902 inch) bearings in the No.3 cylinder block journal position with the main bearing cap. Install the 19.2 mm (0.756 inch) 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.





5. 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.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. 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 10 bolts of the main bearing cap in several passes, in the sequence shown.
Torque: 59 Nm (600 kgf.cm, 43 ft. lbs.)
e. Check that the crankshaft turns smoothly.
8. CHECK CRANKSHAFT THRUST CLEARANCE





9. 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.





10. 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.
11. INSTALL CONNECTING ROD CAP NUTS

HINT:
^ The cap nuts are tightened in 2 progressive steps (steps b. and d.).
^ If any one of the connecting rod bolts 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 2 cap nuts in several passes.
Torque: 25 Nm (250 kgf.cm, 18 ft. lbs.)
If any one of the cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set.





c. Mark the front of the cap nut with the paint.
d. Retighten the cap nuts 90° as shown.
e. Check that the painted mark is now at a 90° angle to the front.
f. Check that the crankshaft turns smoothly.
12. CHECK CONNECTING ROD THRUST CLEARANCE
13. INSTALL ENGINE BALANCER





a. Turn the crankshaft, and set the No.1 cylinder TDC as shown in the illustration.





b. Set the balance shafts so that the punch marks of the balance shafts are aligned with the grooves of the No.2 housing.





c. Wipe clean the installation surface of the spacer.
d. Place the spacers on the cylinder block.

HINT: When replacing the crankshaft and/or balance shaft, use the thickest spacers.





e. Place the engine balancer on the cylinder block.
f. Check that punch marks shown in the illustration of the balance shafts are aligned with the grooves of the No.2 housing.





g. While pulling the center part of the engine balancer in the direction of the arrow, uniformly tighten the 6 bolts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf.cm, 36 ft. lbs.)





h. Recheck that the punch marks of the balance shafts are aligned with the grooves of the No.2 housing.
14. CHECK AND ADJUST BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR. Refer to Valve Clearance; Service and Repair.
15. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 13 Nm (130 kgf.cm, 9 ft. lbs.)





16. INSTALL WATER PUMP, WATER BYPASS PIPE AND OIL COOLER (w/ OIL COOLER) ASSEMBLY
a. Install a new O-ring to the water pump cover.
b. Install the water pump, water bypass pipe and oil cooler (w/ oil cooler) assembly with the 3 bolts. Tighten the bolts in the sequence shown.
Torque: 8.8 Nm (90 kgf.cm, 78 inch lbs.)
c. Install the generator drive belt adjusting bar with the bolt.
Torque: 22 Nm (224 kgf.cm, 16 ft. lbs.)
d. w/ Oil Cooler: Install the oil cooler. Refer to Oil Pump; Service and Repair.
17. INSTALL OIL FILTER. Refer to Oil; Service and Repair.
18. INSTALL KNOCK SENSOR 1
19. INSTALL PS PUMP BRACKET
Install the PS pump bracket with the 3 bolts.
Torque: 43 Nm (440 kgf.cm, 32 ft. lbs.)
20. INSTALL OIL PUMP AND OIL PAN
a. Install the oil pump and oil pan.
b. Install the crankshaft position sensor connector to the generator drive belt adjusting bar.
21. INSTALL OIL DIPSTICK
22. INSTALL CYLINDER HEAD ASSEMBLY
a. Install the cylinder head assembly.
b. Install the 2 bolts holding the water bypass pipe to the cylinder head.
Torque: 19 Nm (195 kgf.cm, 14 ft. lbs.)
c. Install the VSV for EGR to the cylinder head with the bolt.
d. Connect the knock sensor 1 connector.
e. Connect the crankshaft position sensor connector.
f. Install the wire clamp to the generator drive belt adjusting bar.
g. Connect the IAC valve water bypass hose to the water bypass pipe.
h. Connect the water bypass hose (from the water bypass pipe) to the water outlet.
i. Install the camshafts.
j. Install the cylinder head cover.
1. Install the cylinder head cover.
2. Connect the PCV hose to the intake manifold.
k. Install the No.3 timing belt cover with the 3 bolts.
Torque: 7.8 Nm (80 kgf.cm, 69 inch lbs.)
23. INSTALL TIMING BELT AND PULLEYS. Refer to Timing Belt; Service and Repair.
24. DISCONNECT ENGINE FROM ENGINE STAND