Engine Assembly
Reassembly
1. Clean all parts before assembly.
2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.
3. Replace main bearings and rod bearings if they are peeling, burned or otherwise damaged.
Notice: Do not reuse old gaskets or seals.
4. Install one piston pin clip into clip grooves on piston.
5. Insert connecting rod into piston and slide piston pin through piston and through connecting rod until it makes contact with the piston pin clip already installed.
Notice: Verify that piston and rod are assembled in same direction as they were prior to disassembly.
6. Install second piston pin clip into clip grooves on opposite side of piston.
7. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
8. Install three piece oil ring onto piston.
a. Apply clean engine oil to the oil ring expander and upper and lower oil rings.
b. Install expander onto piston so that expander ends face upward.
c. Install lower oil ring onto piston. Ring may be installed with either face upward.
d. Install upper oil ring onto piston. Ring may be installed with either face upward.
9. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.
10. Use a ring expander and install second ring.
11. Use a ring expander and install top ring.
Notice: Top ring and second ring should be installed with "R" mark facing up.
12. Align piston ring gaps as shown.
13. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes and main bearing journals thoroughly, and dry components with compressed air.
14. Install grooved main bearings into saddles on engine block.
15. Install thrust bearings with oil groove facing crankshaft.
16. Set crankshaft on installed bearings.
17. Install remaining main bearings into main bearing caps.
18. Position Plastigage (R) on crankshaft journals.
19. Install main bearing caps along with lower main bearings according to cap number and <- mark.
20. Tighten main bearing cap bolts according to the following procedure:
a. Tighten bolts in order shown.
Tightening torque: 28.9 ft. lbs. (39.2 Nm, 4 kg-m)
b. Loosen bolts in reverse of order shown.
c. Retighten bolts in order shown.
Tightening torque: 14.5 ft. lbs. (19.6 Nm, 2 kg-m)
d. Mark bolts for rotational reference.
e. Rotate bolts 90° (1/4 Turn) in order shown.
f. Rotate bolts another 60° (1/6 Turn) in order shown.
Caution: Do not rotate crankshaft with Plastigage (R) on crankshaft journals.
21. Remove main bearing caps and check bearing clearance.
Notice: The widest point of Plastigage (R) is the smallest clearance, and the narrowest point of Plastigage is the largest clearance.
22. If oil clearance exceeds specification, grind and polish crankshaft and use undersized main bearings.
Oil Clearance: 0.00095 - 0.00165 inch (0.024 - 0.042 mm)
23. Lift crankshaft out of cylinder block and carefully remove Plastigage (R) from main bearings and crankshaft journals.
24. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
25. Apply a light coat of oil on crankshaft main bearing journals and on main bearings on main bearing caps.
26. Install main bearing caps along with lower main bearings according to cap number and <- mark.
27. Tighten main bearing cap bolts according to the following procedure:
a. Tighten bolts in order shown.
Tightening torque: 28.9 ft. lbs. (39.2 Nm, 4 kg-m)
b. Loosen bolts in reverse of order shown.
c. Retighten bolts in order shown.
Tightening torque: 14.5 ft. lbs. (19.6 Nm, 2 kg-m)
d. Mark bolts for rotational reference.
e. Rotate bolts 90° (1/4 Turn) in order shown.
f. Rotate bolts another 60° (1/6 Turn) in order shown.
28. Rotate crankshaft to ensure it does not bind.
29. Place a dial indicator against front of crankshaft and zero gauge.
30. Using a prying tool, move crankshaft forward and zero dial indicator.
31. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial indicator.
End Play: 0.0032 - 0.0111 inch (0.080 - 0.282 mm)
32. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft and thrust bearings.
Thrust bearing width
Thrust bearing size:
Standard: 0.0985 - 0.1003 inch (2.500 - 2.550 mm)
Standard + 0.010 inch (0.25 mm): 0.1034 - 0.1053 inch (2.625 - 2.675 mm)
Standard + 0.020 inch (0.50 mm): 0.1083 - 0.1102 inch (2.750 - 2.800 mm)
Standard + 0.030 inch (0.75 mm): 0.1132 - 0.1151 inch (2.875 - 2.925 mm)
33. Install a bearing into connecting rod.
34. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.
35. Check piston rings for correct end gap stagger.
36. Place piston (cylinder number one) with "F" mark facing front of engine block, then slip piston and connecting rod assembly into a piston ring compressor.
37. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
38. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of engine block.
39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes contact with crankshaft.
Notice: Follow this procedure for remaining piston and connecting rod assemblies.
40. Install a connecting rod bearing in each connecting rod cap.
41. Place a piece of Plastigage (R) on crank pin journals.
42. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.
Tightening torque: 34.7 - 36.9 ft. lbs. (47 - 50 Nm)
Notice: When installing the connecting rods, match marks made on the connecting rod and cap to reference mark made on cylinder block to prevent oil starvation to the connecting rod bearings.
43. Loosen and remove connecting rod caps.
44. Check the connecting rod bearing clearance.
Oil clearance: 0.0008 - 0.0019 inch (0.020 - 0.05 mm)
Maximum: 0.004 inch (0.10 mm)
45. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting rod bearings.
46. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
47. Install connecting rod cap and torque to specification.
Tightening torque: 34.7 - 36.9 ft. lbs. (4.8 - 5.1 kg-m)
48. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod side clearance.
Notice: Do not measure between connecting rod cap and crankshaft.
Side clearance: 0.0044 - 0.0103 inch (0.110 - 0.262 mm)
Maximum: 0.012 inch (0.30 mm)
49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
Exterior engine components
50. Apply a light coat of clean engine oil to rear oil seal.
51. Install rear oil seal into rear cover by hand.
52. Press oil seal into rear cover.
Notice: Oil seal must be pressed in until it is nearly flush with surface of rear cover.
Protrusion: 0.0 - 0.02 inch (0.0 - 0.5 mm)
53. Apply a coat of silicone sealer to rear cover.
Thickness: 0.08 inch (2 mm)
54. Install the rear cover.
Tightening torque: 5.8 - 8.0 ft. lbs. (7.8 - 10.8 Nm, 0.8 - 1.1 kg-m)
55. Remove any sealant that protrudes from rear cover onto oil pan mounting surface.
56. Apply clean engine oil to new front oil seal and oil pump body.
57. Install front oil seal by hand.
58. Press oil seal into oil pump body.
Notice: Oil seal must be pressed in until it is nearly flush with front surface of oil pump body.
Protrusion: 0.02 - 0.04 inch (0.5 - 1.0 mm)
59. Install a new O-ring seal.
60. Apply a bead of silicone sealant to oil pump body as shown.
Thickness: 0.04 - 0.08 inch (1 - 2 mm)
Caution: Oil pump body must be installed within 5 minutes after silicone sealant is applied.
61. Install oil pump with six bolts.
Tightening torque: 14 - 19 ft. lbs. (19 - 26 Nm, 1.9 - 2.6 kg-m)
62. Remove any sealant that protrudes from oil pump onto oil pan mounting surface.
63. Remove all foreign material from water pump mounting surface.
64. Install water pump with a new gasket and torque to specification.
Tightening torque: 14 - 19 ft. lbs. (19 - 26 Nm, 1.9 - 2.6 kg-m)
65. Install oil pressure switch.
Tightening torque: 8.7 - 13.7 ft. lbs. (11.7 - 17.6 Nm, 1.2 - 1.8 kg-m)
66. Apply a small amount of engine oil to rubber seal of oil filter.
67. Install oil filter until rubber seal contacts base and then tighten filter 1 and 1/6 turn using an oil filter wrench.
70. Install oil strainer with a new gasket.
Tightening torque: 5.8 - 8.7 ft. lbs. (7.8 - 11.8 Nm)
71. Remove all foreign material from gasket surface.
72. Apply a continuous bead of silicone sealant to oil pan contact surfaces.
Notice: Install oil pan within five minutes of applying silicone sealer.
73. Install oil pan and tighten oil pan bolts.
Tightening torque: 5.8 - 8.0 ft. lbs. (7.8 - 10.8 Nm, 0.8 - 1.1 kg-m)
74. Clean thread sealant from flywheel bolts and bolt holes in crankshaft.
Notice: If thread sealant cannot be removed from bolt, replace flywheel bolt. If you are using new flywheel bolts, do not apply sealant new bolts have sealant already applied to threads.
75. Install separator plate onto cylinder block.
Tightening torque: 13.7 - 22.4 ft. lbs. (18.6 - 30.4 Nm, 1.9 - 3.1 kg-m)
76. Install flywheel (M/T) or drive plate/backing plate/adapter (A/T) assembly onto crankshaft.
77. Install bolts (apply sealant to reused bolts).
78. Install locking tool.
Fig. 23 Flywheel Tightening Sequence:
79. Tighten bolts in two or three steps to the specified torque.
Tightening torque: 71 - 75.9 ft. lbs. (97 - 103 Nm, 9.8 - 10.5 kg-m)
80. Install clutch disc and clutch cover (M/T).
81. Center the clutch disc with SST or equivalent and torque clutch cover bolts to specification (M/T).
Tightening torque: 16 - 24 ft. lbs. (22 - 32 Nm, 2.2 - 3.3 kg-m)
82. Remove locking tool.
83. Install valve, then slide valve seal over valve stem and onto valve guide.
84. Install valve guide seal installer over valve seal.
Notice: Intake and exhaust valve seals are different. Only exhaust valve seals have four teeth.
Caution: Using a hammer will damage valve seals.
85. Remove the valve guide seal installer.
86. Install lower spring seat on cylinder head.
87. Install HLA protector SST(K95A-1000-E) if available.
88. Install valve spring with narrow spring coils (B) toward cylinder head, and wider coils (A) toward upper spring seat.
89. Install upper spring seat and compress valve spring with SST or equivalent.
90. Install valve locks and release SST or equivalent from valve spring.
91. Tap end of valve stem lightly two or three times with a plastic hammer to verify that valve locks are fully seated.
92. Remove HLA protector (K95A-1000-E) if used. Repeat procedure for remaining valve assembles.
93. Remove all foreign material from contact surface of cylinder head and cylinder block.
94. Place cylinder head gasket onto cylinder block and lower cylinder head onto cylinder block.
95. Install cylinder head bolts.
96. Tighten cylinder head bolts according to following procedure:
Cylinder Head Bolt Tightening Sequence:
a. Tighten cylinder head bolts in order shown.
Tightening torque: 36.1 ft. lbs. (49 Nm, 5 kg-m)
b. Loosen bolts in reverse of order shown.
c. Retighten cylinder head bolts in order shown.
Tightening torque: 28.9 ft. lbs. (39.2 Nm, 4 kg-m)
d. Mark cylinder head bolts for rotational reference.
e. Rotate cylinder head bolts 90° (1/4 Turn) in order shown.
f. Rotate cylinder head bolts another 90° (1/4 Turn) in order shown.
97. Install HLA's.
98. Install new intake manifold gasket.
99. Install intake manifold.
Tightening torque: 13.7 - 18.8 ft. lbs. (18.6 - 25.5 Nm, 1.9 - 2.6 kg-m)
100. Install intake manifold bracket.
Tightening torque: 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)
101. Install generator and generator mounting bolts and adjusting bolt.
102. Install generator belt and adjust it to specification.
Generator drive belt deflection
New: 0.31 - 0.35 inch (8 - 9 mm)
Used: 0.35 - 0.39 inch (9 - 10 mm)
103. Tighten all bolts to specified torque.
Tightening torque:
Mounting bolts: 27 - 38 ft. lbs. (37 - 52 Nm)
Adjusting bolt: 14 - 19 ft. lbs. (19 - 52 Nm)
104. Install front and rear engine hangers.
105. Hang engine with baby crane from engine stand.
106. Install exhaust manifold and coolant bypass pipe.
Tightening torque:
(A): 28.2 - 34 ft. lbs. (38.2 - 46.1 Nm, 3.9 - 4.7 kg-m)
(B): 15.9 - 21 ft. lbs. (21.6 - 28.4 Nm, 2.2 - 2.9 kg-m)
107. Install No.3 engine mount and bracket.
Tightening torque: 54.1 - 75.9 ft. lbs. (73.5 - 102.9 Nm, 7.5 - 10.5 kg-m)
108. Install No.2 engine mount.
Tightening torque: 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)
109. Install transaxle and eight transaxle mounting bolts.
Tightening torque:
4 upper bolts [(1), (2), (3), (4)]: 65.8 - 86.1 ft. lbs. (89 - 116 Nm, 9.1 - 11.9 kg-m)
4 lower bolts [(5), (6), (7), (8)]: 27.5 - 38.3 ft. lbs. (37 - 52 Nm, 3.8 - 5.3 kg-m)
110. Install starter.
Tightening torque: 27 - 38 ft. lbs. (37 - 52 Nm, 3.7 - 5.8 kg-m)
111. Fill with specified type and amount of engine oil and check for leaks.