Part 1

Engine

Special Tool(s):

Special Tool(s):

Special Tool(s):

Material:

Material:

Assembly (Steps 1-36)

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

CAUTION: If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.

1. Install the crankshaft main bearings and the thrust bearing.
^ Lubricate the crankshaft main bearings with clean engine oil.





2. Install the lower main bearings in the bearing caps.

3. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.





Install the crankshaft.

4. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.





Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.





5. Install the main bearing caps in the order in which they were removed.





6. Tighten the bolts in the sequence shown to 35 Nm (26 ft. lbs.) and then rotate an additional 57 degrees.
7. Check the piston to cylinder bore and ring clearance.

8. NOTE: Lubricate the piston rings with clean engine oil.

Install the piston rings.





9. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.





10. Install the connecting rod bearings.





11. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.

12. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.





Using the special tool, install the pistons.
^ Rotate the crankshaft as necessary.

13. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing.
14. Rotate the crankshaft until the piston is at the bottom of its stroke.

15. NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.





Loosen the first nut until the face is approximately 2 mm (0.08 inch) over the end of the bolt.





16. Tap on the nut until the bolt can be removed by hand.
17. Repeat the previous 2 steps for the opposite bolt.





18. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
19. Install the connecting rod cap in its original position.





20. Install and tighten the connecting rod nuts finger-tight.
21. Tighten the connecting rod nuts simultaneously in 2 stages:
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
22. Repeat the previous 4 steps for the remaining connecting rods.
23. Rotate crankshaft until the No. 1 piston is at top dead center.





24. If equipped, install the balance shaft.
1 Position the balance shaft assembly.
2 Install the bolts and tighten to 27 Nm (20 ft. lbs.).

25. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, tip to 7 complete turns of the balance shaft may be required to find the correct position.





Align the timing marks.
^ Install a 4 mm (0.16 inch) pin to hold the shaft in place.





26. If equipped, install the balance shaft chain and crankshaft sprocket.





27. If equipped, install the balance shaft tensioner.
1 Position the balance shaft tensioner.
2 Install the 2 bolts and tighten to 29 Nm (21 ft. lbs.).
3 Position the balance shaft chain guide, install the 2 bolts and tighten to 10 Nm (89 inch lbs.).
^ Remove the pin from the tensioner.





28. Position the oil pump intermediate shaft and the oil pump. Install the 2 bolts.
^ Tighten to 19 Nm (14 ft. lbs.).





29. Install the jackshaft.





30. Install the jackshaft thrust plate and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).





31. Position the LH cassette.





32. Install the front cassette and the bolt.
^ Tighten to 19 Nm (14 ft. lbs.).





33. Position the jackshaft sprocket and chain.





34. Install the jackshaft chain guide and the 2 bolts.
^ Tighten to 19 Nm (14 ft. lbs.).





35. Install the jackshaft chain tensioner and the 2 bolts.
^ Tighten to 9 Nm (80 inch lbs.).





36. Using the special tool, hold the crankshaft.