Disassembly and Assembly: Assembly

Fig 1: Identifying Water Drain Plug, Plug And Washer

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Refer to "COMPONENTS " for symbols in the figure.

• Tighten each plug as specified below.

• Replace washers (1), (5) with new ones.
  CAUTION: Do not reuse washers.
• Apply sealant to the thread of water drain plug (3).

  Use Genuine Liquid Gasket or equivalent. 

• Apply sealant to the thread of plug (4).

  Use high strength thread locking sealant or equivalent. 

• Insert oil jet into cylinder block hole, and tighten the mounting bolt on the corner side (A) first.

Fig 2: Identifying Oil Jet Corner Side Mounting Bolts

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• With drift [outer diameter: approx. 35 mm (1.38 in)], press-fit as far as it will go.
  Fig 3: Installing Pilot Converter

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• Press-fit pilot converter with its chamfered side facing crankshaft as shown in the figure below.

Fig 4: Identifying Pilot Converter Chamfered Side

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1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
2. Install thrust bearings (2) to both sides of the No. 3 journal housing on cylinder block (1).
   Fig 5: Identifying Thrust Bearing, Cylinder Block, Crankshaft, Main Bearing And Oil Groove

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   • Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
3. Install main bearings paying attention to the direction.

• Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on main bearing cap.
• Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
• When installing, align main bearing stopper protrusion to cutout of cylinder block and main bearing.
• Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

• While turning crankshaft by hand, check that it turns smoothly.

• Align the identification number to the journal position to install.
  Fig 6: Identifying Installing Sequence Of Main Bearing Caps

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• Install it with the front mark (indicated by stamping) facing the front of engine.
• Using plastic hammer or similar tool, tap them lightly to seat them on the installation position.
  NOTE: Main bearing cap cannot be replaced as a single parts, because it is machined together with cylinder block.

1. Apply new engine oil to threads and seat surfaces of main bearing cap bolts and sub bolts.
2. Tighten all bolts in order of (No. 1 - 30) temporarily.
   Fig 7: Main Bearing Cap Bolt And Sub Bolt Tightening Sequence

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3. Tighten main bearing cap bolts (M12) in order of No. 1 - 10.

   Torque: 53.9 N.m (5.5 kg-m, 40 ft-lb) 

4. Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20.

   Torque: 19.6 N.m (2.0 kg-m, 14 ft-lb) 

5. Tighten main bearing cap bolts (M12) in order of No. 1 - 10 (clockwise).

   Angle tightening: 90 degrees 

   CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
6. Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20. (clockwise)
   Fig 8: Checking Tightening Angle Of Main Bearing Cap Sub Bolts Using Angle Wrench

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   Angle tightening: 90 degrees 

7. Tighten side bolts (M10) in order of No. 21 - 30.

   Torque: 49.0 N.m (5.0 kg-m, 36 ft-lb) 

• After installing bolts, check that crankshaft can be rotated smoothly by hand.
• Check the crankshaft end play. Refer to "CYLINDER BLOCK ".

• Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to rear oil seal retainer as shown in the figure below.

Fig 9: Identifying Liquid Gasket

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Use Genuine RTV Silicone Sealant or an equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

Fig 10: Identifying Oil Seal Orientation

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• Apply new engine oil to both oil seal lip (A) and dust seal lip (B).
• Install it so that each seal lip is oriented as shown in the figure below.
  CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.
• Press in rear oil seal (1) to the position as shown in the figure below.
  Fig 11: Identifying Rear Oil Seal Installing Area

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• Using a suitable drift [outer diameter: 101 mm (3.98 in)].
• Check the garter spring is in position and seal lips are not inverted.

• Assemble so that the front mark (A) on the piston head and the cylinder number (D) on connecting rod are positioned as shown in the figure below.

Fig 12: Identifying Front Mark, Cylinder Number, And Oil Hole On Piston And Connecting Rod

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1. Using snap ring pliers, install new snap ring to the groove of piston rear side.
   • Insert it fully into groove to install.
2. Install piston to connecting rod.
   • Using an industrial use dryer or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod.
3. Install new snap ring to the groove of the piston front side.

• Insert it fully into groove to install.
• After installing, check that connecting rod moves smoothly.

Fig 13: Installing Piston Rings To Piston Using Piston Ring Expander

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• If there is stamped mark on ring, mount it with marked side up.

  Stamped mark: 

  Top ring (A): 1 K 

  Second ring (B): 2 K 

  Fig 14: Identifying Stamped Mark On Top Ring And Second Ring

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• Position each ring with the gap as shown in the figure below referring to the piston front mark (D).
  Fig 15: Identifying Gap Between Rings

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• Check the piston ring side clearance. Refer to "INSPECTION ".

• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protrusion (B) with cutout (A) of connecting rods and connecting rod bearing caps to install.
• Ensure the oil hole (C) on connecting rod and that on the corresponding bearing are aligned.

Fig 16: Identifying Connecting Rod Bearing Stopper Protrusion, Cutout And Oil Hole

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• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Be sure that front mark on piston crown is facing the front of the engine.
• Using a piston ring compressor [SST: EM03470000 (J-8037)] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the engine.
  CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
  Fig 17: Installing Piston And Connecting Rod Assembly

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• Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
  Fig 18: Identifying Stamped Cylinder Number, Codes And Diameter Grades On Connecting Rod Bearing Cap

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• Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.

1. Inspect the outer diameter of connecting rod bolt. Refer to "INSPECTION ".
2. Apply engine oil to the threads and seats of connecting rod bolts.
3. Tighten connecting rod bolts.

   Torque: 28.4 N.m (2.9 kg-m, 21.0 ft-lb) 

4. Completely loosen connecting rod bolts.

   Torque: 0 N.m (0 kg-m, 0 ft-lb) 

5. Tighten connecting rod bolts.

   Torque: 24.5 N.m (2.5 kg-m, 18.0 ft-lb) 

6. Tighten connecting rod bolts. (clockwise)

   Angle tightening: 90 degrees 

   CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Never make judgment by visual inspection.

• After tightening connecting rod bolts, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to "INSPECTION ".

• Install knock sensors in the direction shown in the figure below.
  Fig 19: Identifying Knock Sensors

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• After installing knock sensor, connect harness connector, and lay it out to front of the engine.
  CAUTION:

  • Never tighten mounting bolts while holding connector.
  • If any impact by dropping is applied to knock sensor, replace it with new one.
  NOTE:

  • Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
  • Check that knock sensor does not interfere with other parts.

• Install drive plate (4) and reinforcement plate (3) as shown in the figure below.
  Fig 20: Identifying Pilot Converter, Drive Plate And Reinforcement Plate

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• When installing drive plate to crankshaft (1), be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
  CAUTION: If these are not aligned correctly, engine runs roughly and "MI" illuminates.
• Holding ring gear with the ring gear stopper [SST: KV10119200 (J-49277)].
• Tighten the mounting bolts crosswise over several times.