Reassembly
Reassembly
NOTE:
- Thoroughly clean all parts to assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.
(1) Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.
CAUTION:
- Take care that piston pin is not to be damaged during pressing process.
- When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner diameter as below.
Piston pin outer DIA. :
21.001 - 21.006mm (0.8268 - 0.8270in)
Connecting rod small end inner DIA. :
20.974 - 20.985mm (0.8257 - 0.8261in)
(2) Use a hydraulic press for installation.
(3) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install the piston rings.
(1) Install the oil ring spacer and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
4. Install the main bearings.
NOTE:
Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).
(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5. Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
6. Place the crankshaft(A) on the cylinder block.
7. Place the main bearing caps on cylinder block.
8. Install the main bearing cap bolts.
Tightening torque
14.7Nm (1.5kgf.m, 10.8lb-ft) + 27.5 - 31.4Nm (2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft) + 120 - 125°
NOTE:
- The main bearing cap bolts are tightened in 2 progressive steps.
- If any of the bearing cap bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. (with specified torque 29.4N.m (3.0kgf.m, 21.7lb-ft))
(3) Retighten the bearing cap bolts by 120° in the numerical order shown.
(4) Check that the crankshaft turns smoothly.
9. Check crankshaft end play.
10. Install piston and connecting rod assemblies.
NOTE:
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
(2) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
17.7 - 21.6Nm (1.8 - 2.2kgf.m, 13.0 - 15.9lb-ft) + 88 - 92°
NOTE:
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
11. Apply liquid gasket to the mating surface of cylinder block and ladder frame.
NOTE:
- When assembling ladder frame, the liquid sealant Loctite 5900H or THREEBOND 1217H should be applied ladder frame.
- The part must be assembled within 5 minutes after sealant was applied.
- Apply sealant to the inner threads of the bolt holes.
12. Install ladder frame(A) with 10 bolts in several passes in sequence shown.
Tightening torque
Step 1 :
7.8 - 8.8N.m (0.8 - 0.9kgf.m, 5.8 - 6.5lb-ft)
Step 2 :
15.7 - 18.6N.m (1.6 - 1.9kgf.m, 11.6 - 13.7lb-ft)
Step 3 :
23.5 - 27.5N.m (2.4 - 2.8kgf.m, 17.4 - 20.3lb-ft)
13. Install rear oil seal.
(1) Apply engine oil to a new oil seal lip.
(2) Using SST(09231-H1100, 09214-3K100) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
14. Install CKP sensor(A) and sensor cover.
Tightening torque
3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
15. Install oil pressure sensor.
(1) Apply adhesive to 2 or 3 threads.
Adhesive : MS 721-39(B) or equivalent.
(2) Install the oil pressure sensor (A).
Tightening torque
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
16. Install knock sensor(A).
Tightening torque
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 13.4lb-ft)
17. Install oil level gauge assembly.
(1) Install a new O-ring on the oil level gauge.
(2) Apply engine oil on the O-ring.
(3) Install the oil level gauge assembly(A) with the bolt.
Tightening torque
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
18. Install tensioner assembly integrated bracket(A).
Tightening torque
39.2 - 44.1N.m (4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)
19. Install the water pump (A) with a new water pump gasket.
Tightening torque :
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
20. Install the power steering pump and the bracket.
21. Install the alternator (A).
Tightening torque :
49.0 - 63.7N.m (5.0 - 6.5kgf.m, 36.2 - 47.0lb-ft)
22. Install the oil pump.
23. Install the cylinder head assembly.
24. Install the timing chain.
25. Install the oil pan.
(1) Using a razor blade and gasket scraper, remove all the old gasket material from the gasket surfaces.
NOTE:
Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket LOCTITE 5900H or THREEBOND 1217H equivalent (MS721-40).
NOTE:
- To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque :
M8 bolts : 26.5 - 30.4N.m (2.7 - 3.1kgf.m, 19.5 - 22.4lb-ft)
M6 bolts : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
26. Install the A/C compressor.
27. Install the intake manifold and exhaust manifold.
28. Install the drive plate (AT only) or fly wheel (MT only).
Tightening torque :
117.7 - 127.5N.m (12 - 13kgf.m, 86.8 - 94.0lb-ft)
NOTE:
- Always use new flywheel (drive plate) bolts(C).
- Apply sealant to the screw part (8mm from the end of the bolt) when using new flywheel bolts.
Sealant:Three bond 2403, Loctite 200 or 204
- Install and uniformly tighten the 7 bolts, in several passes.
29. Install the engine assembly on the vehicle.
Add all fluids to their normal operating levels.