Assembly
CYLINDER BLOCK ASSEMBLY
NOTE:
- Thoroughly clean all parts to be 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.
- Apply a generous amount of oil on the sliding surface of the bearing, and not on the back of it or on the surface to which it is installed.
1. Install main bearings as follows:
NOTE:
- Main bearings come in widths of 20.0 mm (0.787 inch) and 23.0 mm (0.906 inch). Install the 23.0 mm bearings in the No.1 cylinder block journal position with the main bearing cap. Install the 20.0 mm bearings in the other positions.
- Upper bearings have an oil groove and oil holes, lower bearings do not.
(a) Align the bearing claw with the claw groove of the main bearing cap or cylinder block.
NOTE: Install the bearing with the oil hole in the cylinder block.
(b) Install the bearings in the cylinder block and main bearing caps.
2. Install the 2 thrust washers under the No. 4 main journal position of the cylinder block with the oil grooves facing outward.
3. Place crankshaft on cylinder block.
4. Install main bearing cap and lower thrust washers as follows:
A. Place main bearing cap and lower thrust washers on cylinder block:
(a) Install the lower thrust washers on the No.4 main bearing with the grooves facing outward.
(b) Install the main bearing caps in numerical order with the arrows facing forward.
B. Install main bearing cap bolts:
NOTE:
- The main bearing cap bolts are tightened in 2 progressive steps.
- If any of the main bearing bolts break or deform, replace them.
(a) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 14 main bearing cap bolts, in several passes, in the sequence shown to 44 Nm (33 ft. lbs.).
NOTE: If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolt head with paint.
(d) Retighten the main bearing cap bolts 90° in the numerical order shown above.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
5. Check crankshaft thrust clearance as follows:
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020-0.220 mm (0.0008-0.0087 inch).
Maximum thrust clearance: 0.30 mm (0.0118 inch).
(b) If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 1.940-1.990 mm (0.0764-0.0783 inch).
6. Using a suitable piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
7. Install connecting rod caps as follows:
A. Place connecting rod cap on connecting rod:
(a) Match the numbered connecting rod cap with the connecting rod.
(b) Install the connecting rod cap with by aligning the dowel pin to the corresponding hole.
B. Install connecting rod cap bolts:
NOTE:
- The connecting rod cap bolts are tightened in 2 progressive steps.
- If any of the connecting rod bolts break or deform, replace them.
(a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the bolts of the connecting rod cap in several passes to 29 Nm (22 ft. lbs.).
NOTE: If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolt.
(c) Mark the front of the connecting rod cap bolt with paint.
(d) Retighten the connecting rod cap bolts 90° in the numerical order shown.
(e) Check that the painted mark is now at a 90°.
(f) Check that the crankshaft turns smoothly.
8. Check connecting rod thrust clearance as follows:
(a) Using a suitable dial indicator, measure the thrust clearance while moving the connecting rods back and forth.
Standard thrust clearance: 0.250-0.402 mm (0.0098-0.0158 inch).
Maximum thrust clearance: 0.50 mm (0.0197 inch).
(b) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s).
(c) If necessary, replace the crankshaft.
Connecting rod thickness: 25.898-25.950 mm (1.0196-1.0217 inch).
9. Install rear oil seal retainer as follows:
A. Remove any old packing (FIPG) material:
(a) Be careful not to drop any oil on the contact surfaces of the retainer and cylinder block.
(b) Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
(c) Thoroughly clean all components to remove all debris.
(d) Using a non-residue solvent, clean both sealing surfaces.
B. Apply seal packing Part No. 08826-00080, or equivalent, to the retainer as shown in the illustration:
(a) Install a nozzle that has been cut to a 2-3 mm (0.08-0.12 inch) opening.
(b) Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
(c) Immediately remove nozzle from the tube and reinstall cap.
C. Install the retainer with the 6 bolts, tighten to 5.9 Nm (52 inch lbs.).
AFTER CYLINDER BLOCK ASSEMBLY
1. Install oil pump, refer to Engine Lubrication.
2. Install fuel pipe support, tighten to 28 Nm (21 ft. lbs.).
3. Install RH engine mounting bracket and insulator assembly, tighten to 58 Nm (43 ft. lbs.).
4. Install LH engine mounting bracket and insulator assembly, tighten to 58 Nm (43 ft. lbs.).
5. Install oil filter and bracket assembly, tighten to 88 Nm (65 ft. lbs.).
6. Install oil pressure switch and knock sensors as follows:
(a) Install the union nut with a new gasket, tighten to 55 Nm (41 ft. lbs.).
(b) Apply LOCTITE 242, or equivalent, adhesive to 2 or 3 threads of the oil pressure switch.
(c) Using socket wrench Special Service Tool (SST) No. 09816-30010, or equivalent, switch and sensors, tighten as follows:
Oil pressure switch: 14 Nm (11 ft. lbs.).
Knock sensor: 44 Nm (33 ft. lbs.).
7. Install cylinder head, refer to Cylinder Head Assembly.
8. Install water pump, refer to Cooling System
9. Install No. 2 water bypass pipe with hose as follows:
(a) Install the water bypass pipe with the bolt and 2 nuts, tighten to 21 Nm (15 ft. lbs.).
(b) Connect the water bypass hose to the engine hanger.
10. Install timing pulleys and belt, refer to Timing components.
11. Install alternator, tighten to 37 Nm (27 ft. lbs.).
12. Remove engine from engine stand.
Drive Plate And Rear Plate Installation:
13. Install drive plate as follows:
(a) Install the front spacer, drive plate and rear plate on the crankshaft.
(b) Apply thread lock adhesive THREE BOND 1324, or equivalent, to 2 or 3 threads of the mounting bolt end.
Drive Plate Bolt Tightening Sequence:
(c) Install and uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown to 83 Nm (61 ft. lbs.).