Reassembly

REASSEMBLY

HINT:
- Thoroughly clean all the parts to be assembled.
- Before installing the parts, apply fresh engine oil to all the sliding and rotating surfaces.
- Replace all the 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 at one end of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.





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 on 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 end of the piston pin hole.

NOTICE: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

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 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 CONNECTING ROD 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: Upper bearings have an oil groove and oil holes, however 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.
- Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.





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

NOTICE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.





5. INSTALL 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





a. Install the 5 main bearing caps in their proper location.

HINT: A number is marked on each main bearing cap to indicate the installation position.

b. Install the main bearing cap bolts.

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

1) Apply light coat of engine oil on the threads and under the bearing cap bolts.





2) Install and uniformly tighten the 10 main bearing cap bolts in several passes, in the sequence shown.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
3) Mark the front of the main bearing cap bolts with paint.





4) Retighten the main bearing cap bolts by 90°in the numerical order shown in the illustration.
5) Check that the painted mark is now at a 90°angle to the front.
c. Check the crankshaft turns smoothly.
8. CHECK CRANKSHAFT THRUST CLEARANCE





9. 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.





10. INSTALL CONNECTING ROD CAP
Place the connecting rod cap on the connecting rod.
1) Match the numbered connecting rod cap with the connecting rod.
2) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.

NOTICE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.





3) Check that the protrusion of the connecting rod cap faces in the correct direction.
4) Install the connecting rod cap bolts.

HINT:
- The connecting rod cap bolts are tightened in 2 progressive steps (steps (3) and (4)).
- If any of the connecting rod cap bolts is broken or deformed, replace it.





5) Apply a light coat of engine oil on the threads an under the heads of the connecting rod cap bolts.
6) Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
7) Mark the front of the connecting cap bolts with paint.





8) Retighten the cap bolts by 90° as shown in the illustration.
9) Check that the painted mark is now at a 90°angle to the front.
10 Check that the crankshaft turns smoothly.
11. CHECK CONNECTING ROD THRUST CLEARANCE
12. INSTALL BALANCE SHAFT BEARINGS
a. Align the bearing claw with the claw groove, and push in the 8 bearings.
b. Apply a light coat of engine oil on the bearings.





13. INSTALL BALANCE SHAFT TO CRANK CASE
a. Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.
b. Place the No. 1 and No. 2 balance shaft on the crank case.
14. INSTALL BALANCE SHAFT HOUSING TO CRANK CASE





a. Install the balance shaft housing bolts.

HINT:
- The balance shaft housing bolts are tightened in 2 progressive steps (step (b) and (d)).
- If any of the balance shaft housing bolts is broken or deformed, replace it.

b. Apply a light coat of engine oil on the threads and under the heads of the balance shaft housing bolts.
c. Install and uniformly tighten the 8 bolts, several passes, in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)
d. Mark the front of the balance shaft housing bolts with paint.





e. Retighten the bolts by 90° as shown in the illustration.
f. Check that the painted mark is now at a 90°angle to the front.
g. Check that the balance shaft turns smoothly.
h. Turn the balance shafts, and check that the timing marks of No. 1 and No. 2 balance shafts are in straight line on the crank case surface as shown in the illustration.
15. INSTALL CRANK CASE AND BALANCE SHAFT ASSEMBLY





a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the crank case 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 the components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the crank case or cylinder block as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 2.5 - 3.0 mm (0.10 - 0.12 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.





c. Install a new O-ring to the cylinder block.





d. Setting the crankshaft No. 1 journal and balance shaft timing mark at 6 o'clock.





HINT: With the crankshaft key positioned at 6 o'clock, check that the timing mark of balance shaft are in the straight line on the crankcase surface.





e. Temporarily install the crank case with the 11 bolts.

HINT: Each bolt length is indicated in the illustration.

Bolt length:
112 mm (4.41 inch) for A of 12 mm head
35 mm (1.38 inch) for B of 12 mm head





f. Install and uniformly tighten the 11 bolts, in several passes, in the sequence shown.
Torque: 32.5 Nm (330 kgf-cm, 24 ft. lbs.)





16. INSTALL OIL FILTER UNION
Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 29.5 Nm (300 kgf-cm, 22 ft. lbs.)
17. INSTALL ENGINE WIRE CLAMP
18. INSTALL KNOCK SENSOR
19. INSTALL OIL PUMP





20. INSTALL ENGINE COOLANT DRAIN UNION
a. Apply adhesive to 2 or 3 threads of union.
Seal packing: Part No. 08826-00100 or equivalent
b. Install the drain union.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.) or more

HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.

Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
21. INSTALL WATER BY-PASS PIPE NO. 1
Install a new gasket and the water by-pass pipe No. 1 with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
22. INSTALL OIL LEVEL GAUGE AND GUIDE
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
23. INSTALL THERMOSTAT
24. INSTALL WATER PUMP





25. INSTALL OCV FILTER
Using a 12 mm hexagon wrench, install the OCV filter with a new gasket and the plug.
26. INSTALL ENGINE WIRE
27. INSTALL CYLINDER HEAD
28. INSTALL TIMING CHAIN
29. REMOVE ENGINE STAND