Part 2
EngineAssembly (Steps 37-72)
37. Install the jackshaft sprocket bolt and tighten in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
38. Install the oil pump drive and the bolt.
^ Tighten to 19 Nm (14 ft. lbs.).
39. Position the RH cassette.
40. Position the rear jackshaft sprocket and the spacer on the jackshaft.
^ Loosely install the bolt.
41. Install the RH cassette bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
42. Using the special tool, hold the crankshaft.
43. Tighten the rear jackshaft sprocket bolt in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
44. Install the jackshaft plug.
45. Position a new engine front cover gasket on the cylinder block.
46. NOTE: Apply thread sealant to the stud bolts and make sure that the stud bolts are installed in their original positions.
Position the front cover and loosely Install the 5 bolts and the 5 stud bolts.
47. Use the special tool to align the front cover and tighten the bolts and stud bolts to 19 Nm (14 ft. lbs.).
48. NOTE: Lubricate the seal lip with clean engine oil.
Using the special tools, install the crankshaft front oil seal.
49. Apply silicone gasket and sealant to the front cover in 4 places.
50. Apply silicone gasket and sealant to the rear main bearing cap as shown.
^ Position the lower block cradle gasket.
51. CAUTION: Failure to back off the set screws can result in damage to the cylinder block cradle.
Back the set screws off until they are below the cylinder block cradle boss.
52. Position the lower block cradle and a new gasket.
53. Install and hand-tighten the 20 bolts and 2 nuts.
54. Install and hand-tighten the bolts.
55. NOTE: The lower block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 inch) lower block cradle under flush or 0.05 mm (0.00196 inch) lower block cradle protrusion.
Using a straightedge, align the transmission face of the lower block cradle with the rear face of the cylinder block.
56. Tighten the 20 bolts and the 2 nuts.
^ Tighten the bolts with washers and both nuts to 10 Nm (89 inch lbs.).
^ Tighten the bolts without washers to 14 Nm (10 ft. lbs.).
57. Install the 2 block cradle bolts.
^ Tighten to 10 Nm (89 inch lbs.).
58. Tighten the lower block cradle inserts to 3 Nm (27 inch lbs.).
59. Install new seals on the 2 silver bolts and loosely install them in the cylinder block cradle.
60. Loosely install the 6 remaining lower block cradle bolts.
61. Tighten the cylinder block cradle bolts in 2 stages.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 34 Nm (25 ft. lbs.).
62. NOTE: Assemblies that measured out of specification must have the entire assembly procedure repeated.
Measure the step between the rear face of the cylinder block and the transmission face of the lower block cradle.
63. Repair all assemblies that exceed under flush specification by installing shims on 1 or both sides of the cylinder block cradle.
64. Install the oil pump screen and pickup tube and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
65. Install the gasket, oil pan and the 10 bolts.
^ Tighten to 9 Nm (80 inch lbs.).
66. Inspect and install new oil filter adapter O-ring seals if necessary.
67. Install the oil filter adapter and the bolt.
^ Tighten to 57 Nm (42 ft. lbs.).
68. Install a new oil filter.
^ Tighten until the oil filter seal is flush with the adapter and then tighten an additional 270 degrees.
69. Using the special tool, install the crankshaft pulley.
70. CAUTION: A new bolt must be used each time it is removed.
Using the special tool, tighten the bolt in 2 stages.
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Rotate an additional 90 degrees.
71. Position the crankshaft position (CKP) sensor and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
72. NOTE: LH side shown, RH side similar.
Position the cylinder head gaskets.