Part 1

ENGINE UNIT

REASSEMBLY





1. INSTALL TIGHT PLUG

NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.

a. Apply adhesive around the tight plugs.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.





b. Using SST, tap in the tight plugs.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07100)

2. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

Standard Protrusion:

3. INSTALL STUD BOLT





a. Using an E8 torx socket wrench, install the stud bolt.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)





4. INSTALL NO.1 SUB-ASSEMBLY OIL NOZZLE
a. Using a 5 mm hexagon wrench and socket wrench, install the oil nozzles.
Torque: 9.0 Nm (92 kgf-cm 80 inch lbs.)





5. INSTALL WITH PIN PISTON SUB-ASSEMBLY
a. Using a screwdriver, install a new snap ring at one end of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.





b. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).





c. Coat the piston pin with engine oil.
d. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

HINT: The piston and pin are a matched set.





e. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.





f. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.





6. INSTALL PISTON RING SET
a. Install the oil ring expander by hand.
b. Using a piston ring expander, install the oil ring rail.
c. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

NOTICE: Do not align the ring ends.





d. Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE: Do not align the ring ends.





7. INSTALL CRANKSHAFT BEARING

NOTICE: Main bearings come in widths between 18.0 mm (0.709 inch) and 21.0 mm (0.827 inch). Install the 21.0 mm (0.827 inch) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 inch) bearings in the No.2 and No.3 positions.

a. Clean the main journal and the both surfaces of the bearing.





b. Install the upper bearing.
(1) Install the upper bearing to the cylinder block as shown in the illustration.

NOTICE: Do not apply engine oil to the bearing and its contact surface.





c. Install the lower bearing.
(1) Install the lower bearing to the bearing cap.
(2) Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 inch) or less.

NOTICE: Do not apply engine oil to the bearing's contact area and backside.





8. INSTALL CRANKSHAFT
a. Install the crankshaft thrust washer to the cylinder block.
(1) Install the 2 thrust washers under the No.2 journal position of the cylinder block with the oil grooves facing outward.
b. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.





c. Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block.

HINT: A number is marked on each main bearing cap to indicate the installation position.

d. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts.
e. Temporarily install the 8 main bearing cap bolts to the inside positions.





f. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 inch) by marking the 2 internal bearing cap bolts as a guide.
Bolt length: 98.50 to 100.50 mm (3.87 to 3.95 inch)





g. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
h. Apply a light coat of engine oil on the threads and under the head of 8 main bearing cap bolts.





i. Install the 8 main bearing cap bolts to the outside positions.
Bolt length:
98.50 to 100.50 mm (3.87 to 3.95 inch) for bolt A
104.0 to 106.0 mm (4.09 to 4.17 inch) for bolts except A





j. Install the crankshaft bearing cap bolts.

HINT: The main bearing cap bolts are tightened in 2 progressive steps.

k. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm 45 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specified, replace it.





l. Mark the front of the bearing cap bolts with paint.
m. Retighten the bearing cap bolts by 90° in the order above.
n. Check that the painted mark is now at a 90° angle to the front.
o. Check that the crankshaft turns smoothly
p. Check the crankshaft thrust clearance.





q. Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 26 Nm (265 kgf-cm 19 ft. lbs.)
Bolt length: 45 mm (1.77 inch)
r. Check that the crankshaft turns smoothly.
s. Check the crankshaft thrust clearance.





9. INSTALL CONNECTING ROD BEARING
a. Install the connecting rod bearing to the connecting rod and bearing cap.





b. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edge and the connecting rod bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 inch) or less

NOTICE: Do not apply engine oil to the bearing's contact area and backside.

10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
b. Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE: Do not align the ring ends.





c. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

NOTICE: Match the numbered connecting rod cap with the connecting rod.





d. Check that the front mark of the connecting rod cap is facing forward.
e. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
f. Install the connecting cap bolts.

HINT: The connecting cap bolts are tightened in 2 progressive steps.





g. Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





h. Mark the front side of each connecting cap bolt with paint.
i. Retighten the cap bolts by 90° as shown in the illustration.
j. Check the painted mark is now at a 90° angle to the front.
k. Check that the crankshaft turns smoothly
l. Check the connecting rod thrust clearance.





11. INSTALL RING PIN
a. Using a plastic hammer, tap in a new ring pins to the specified protrusion height.
Specified protrusion height: 2.5 to 3.8 mm (0.098 to 0.150 inch)





12. INSTALL NO.1 WITH HEAD STRAIGHT SCREW PLUG
a. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)





13. INSTALL NO.2 WITH HEAD STRAIGHT SCREW PLUG
a. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)





14. INSTALL UNION
a. Apply adhesive to the union of the cylinder head.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.





b. Install the union to the cylinder head as shown in the illustration.
Torque: 15 Nm (153 kgf-cm 11 ft. lbs.)





15. INSTALL STUD BOLT

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

a. Using E6 and E8 torx socket wrenches, install the stud bolts.
Torque:
10 Nm (102 kgf-cm 7 ft. lbs.) for bolts A, B and D
4.0 Nm (41 kgf-cm 35 inch lbs.) for bolt C





16. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap in a new straight pin as shown in the illustration.
Specified protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 inch)

17. INSTALL VALVE SPRING SEAT
a. Install the valve spring seats to the cylinder head.





18. INSTALL VALVE STEM OIL SEAL
a. Apply a light coat of engine oil to new oil seals.

NOTICE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

HINT: The intake valve oil seals are white and the exhaust valve oil seals are black.





b. Using SST, push in the oil seals.
SST 09201-41020

NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.





19. INSTALL INTAKE VALVE
a. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
b. Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.





c. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)





d. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.





20. INSTALL EXHAUST VALVE
a. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
b. Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.





c. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)





d. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.

21. INSTALL VALVE STEM CAP
a. Apply a light coat of engine oil to the valve stem caps.
b. Install the valve stem caps to the cylinder head.





22. INSTALL REAR ENGINE OIL SEAL RETAINER
a. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.





b. Install the oil seal retainer with the 6 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

NOTICE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent





23. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY
a. Install the water outlet pipe with the 2 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)





24. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH
a. Install the cylinder block water jacket spacer LH as shown in the illustration.

HINT: Be sure to face the slope to front of the engine.

25. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH
a. Install the cylinder block water jacket spacer RH as shown in the illustration.

HINT: Be sure to face the slope to front of the engine.





26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
a. Apply a continuous bead of the seal packing (diameter 2.5 to 3.0 mm (0.098 to 0.118 inch)) to a new cylinder head gasket as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head gasket within 3 minutes after applying the seal packing.
^ Install the cylinder head bolt within 15 minutes after applying the seal packing.
^ Do not apply engine oil within 2 hours of installation.





b. Place the cylinder head gasket on the cylinder block surface with the Lot No.stamp upward.

NOTICE:
^ Be careful of the installation direction.
^ Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

c. Place the cylinder head on the cylinder block.

NOTICE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT: The cylinder head bolts are tightened in 3 progressive steps.

d. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





e. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm 27 ft. lbs.)





f. Mark the cylinder head bolt head with paint as shown in the illustration.
g. Tighten the cylinder head bolts another 90°.
h. Tighten the cylinder head bolts by an additional 90°.
i. Check that the painted mark is now facing rearward.





j. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.





27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
a. Apply a continuous bead of the seal packing (diameter 2.5 to 3.0 mm (0.098 to 0.118 inch)) to a new cylinder head gasket as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head gasket within 3 minutes after applying the seal packing.
^ Install the cylinder head bolt within 15 minutes after applying the seal packing.
^ Do not apply engine oil within 2 hours of installation.





b. Place the cylinder head gasket on the cylinder block surface with the Lot No.stamp upward.

NOTICE:
^ Be careful of the installation direction.
^ Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

c. Place the cylinder head on the cylinder block.

NOTICE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT: The cylinder head bolts are tightened in 3 progressive steps.

d. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





e. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm 27 ft. lbs.)





f. Mark the cylinder head bolt head with paint as shown in the illustration.
g. Tighten the cylinder head bolts by 90°.
h. Tighten the cylinder head bolts by an additional 90°.
i. Check that the painted mark is now facing rearward.





j. Tighten the 2 bolts in the order shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

NOTICE: Do not use the tightening procedure for a plastic region bolt when tightening bolts 1 and 2 shown in the illustration.





k. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.





28. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
^ Keep the lash adjuster free from dirt and foreign objects.
^ Only use clean engine oil.

a. Place the lash adjuster into a container full of engine oil.
b. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
SST 09276-75010
c. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
d. Check the movement of the plunger and bleed the air.
OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

e. After bleeding the air, remove SST Then, try to quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
f. Install the lash adjusters.

NOTICE: Install the lash adjuster to the same place it was removed from.





29. INSTALL NO.1 VALVE ROCKER ARM SUB-ASSEMBLY
a. Apply engine oil to the lash adjuster tip and valve stem cap end.
b. Make sure that the valve rocker arm is installed as shown in the illustration.





30. INSTALL CAMSHAFT BEARING CAP RH
a. Apply engine oil to the camshaft journal, camshaft housing and bearing cap.
b. Install the camshaft and camshaft No.2 to the camshaft housing RH.
c. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





d. Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)