Disassembly and Assembly: Assembly

• Apply sealant to the thread of water drain plugs (1) (4).

  Use Genuine RTV Silicone Sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

• Apply sealant to the thread of plugs.

  Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

• Replace washers (2) with new one.

  3 : plug

  <=: Engine front

  Fig 1: Identifying Water Drain Plugs

  
• Tighten each plug as specified below.
  TIGHTENING TORQUE
  
  

  Part	Washer	Tightening torque
  1	No	19.6 N.m (2.0 kg-m, 14 ft-lb)
  3	Yes	78.0 N.m (8.0 kg-m, 58 ft-lb)
  4	Yes	12.3 N.m (1.3 kg-m, 9 ft-lb)

• Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.

  <=: Engine front

  Fig 2: Identifying Oil Jet Dowel Pin

  

1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
2. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block.
   1. No. 1
   2. No. 2
   3. No. 3
   4. No. 4

      F: Thrust bearing installation position

      <=: Engine front

      Fig 3: Identifying Thrust Bearings

      
   • Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).
3. Install main bearings paying attention to the direction.

   A : Cylinder block side

   D : Lower cylinder block side

   <=: Engine front

   Fig 4: Identifying Oil Hole And Groove

   
   • Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on lower cylinder block.
   • Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
   • When installing, align main bearing stopper protrusion to cutout of cylinder block and lower cylinder block.
   • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

• While turning crankshaft by hand, check that it turns smoothly.

• Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to lower cylinder block as shown in the figure.

  a : 3.5 - 4.5 mm (0.138 - 0.177 in) dia

  B : Apply to end

  Use Genuine RTV Silicone Sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

  Fig 5: Applying Continuous Bead Of Liquid Gasket To Lower Cylinder Block

  

<=: Engine front

Fig 6: Lower Cylinder Block Bolt Tightening Sequence

1. Inspect the outer diameter of lower cylinder block bolt. Refer to , "MAIN BEARING ".
2. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
3. Tighten lower cylinder block bolts (No. 1 to 16) in numerical order as shown in the figure.
   NOTE: Use TORX socket (size E14) for bolts No. 1 to 16.

   (Torque spec): 35.3 N.m (3.6 kg-m, 26 ft-lb) 

4. Turn lower cylinder block bolts (No. 1 to 16) 90 degrees clockwise (angle tightening).
   CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Do not make judgment by visual inspection.
5. Completely loosen lower cylinder block bolts (No. 1 to 16).

   (Torque spec): 0 N.m (0 kg-m, 0 ft-lb) 

   CAUTION: In step "e", loosen lower cylinder block bolts (No. 1 to 16) in reverse order of that indicated in the figure.
6. Repeat step  c.
7. Repeat step  d.
8. Tighten lower cylinder block bolt (No. 17 to 26).

   (Torque spec): 22.0 N.m (2.2 kg-m, 16 ft-lb) 

   Fig 7: Checking Lower Cylinder Block Bolt Torque

   
   • After installing lower cylinder block bolts, make sure that crankshaft can be rotated smoothly by hand.
   • Check the crankshaft end play. Refer to , "CYLINDER BLOCK ".

1. Using a snap ring pliers, install new snap ring to the groove of piston rear side.
   • Insert it fully into groove to install.
2. Install piston to connecting rod.
   • Using an industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approx. 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod.
   • Assemble so that the front mark on the piston head and the cylinder number on connecting rod are positioned as shown in the figure.
     1. Piston grade number
     2. Front mark
     3. Pin grade number
     4. Cylinder number
     5. Front mark

        <=: Engine front

        Fig 8: Identifying Front Mark On Piston Head

        
3. Install new snap ring to the groove of the piston front side.
   • Insert it fully into groove to install.
   • After installing, make sure that connecting rod moves smoothly.

• If there is stamped mark on ring, mount it with marked side up.

  Stamped mark: 

  Top ring (A) : 1 N 

  Second ring (B) : 2 N 

  Fig 10: Identifying Stamped Mark On Ring

  
• Position each ring with the gap as shown in the figure referring to the piston front mark (D).
  1. 90 degrees
  2. 45 degrees

     C :Top ring gap

     E :Oil ring upper or lower rail gap (either of them)

     F :Second ring and oil ring spacer gap

     Fig 11: Identifying Piston Ring Gap Direction

     
• Check the piston ring side clearance. Refer to , "CYLINDER BLOCK ".

• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protrusion (B) with cutout (C) of connecting rods and connecting rod bearing caps to install.
• Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
  Fig 12: Identifying Connecting Rod Bearing Stopper Protrusion And Cutout Of Connecting Rods

  

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Be sure that front mark on piston crown is facing front of engine.
• Using a piston ring compressor [SST: EM03470000 (J8037)] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the engine.
  CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
  Fig 13: Installing Piston

  

• Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
  1. Sample codes
  2. Bearing stopper groove
  3. Small-end diameter grade
  4. Big-end diameter grade
  5. Weight grade
  6. Cylinder No.
  7. Management code

     I :Management code

     Fig 14: Identifying Stamped Cylinder Number Marks On Connecting Rod

     
• Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.

1. Inspect the outer diameter of connecting rod bolt. Refer to , "CYLINDER BLOCK ".
2. Apply engine oil to the threads and seats of connecting rod bolts.
3. Tighten connecting rod bolts.

   (Torque spec): 28.4 N.m (2.9 kg-m, 21 ft-lb) 

4. Completely loosen connecting rod bolts.

   (Torque spec): 0 N.m (0 kg-m, 0 ft-lb) 

5. Tighten connecting rod bolts.

   v: 24.5 N.m (2.5 kg-m, 18 ft-lb) 

6. Then turn connecting rod bolts 90 degrees clockwise (angle tightening).
   CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653- A)] (A). Avoid tightening based on visual check alone.
   • After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
   • Check the connecting rod side clearance. Refer to , "CYLINDER BLOCK ".
     Fig 15: Checking Connecting Rod Bolts Torque

     

• Apply new engine oil to both oil seal lip and dust seal lip.

• With a drift of the following outer diameter, press-fit as far as it will go.

  Pilot bushing : Approx. 17 mm (0.67 in) 

  Pilot converter : Approx. 33 mm (1.30 in) 

  Fig 16: Installing Pilot Converter

  
• Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)

  <=: Crankshaft side

  Fig 17: Identifying Pilot Converter With Chamfer Facing Crankshaft

  
• Press-fit pilot bushing (1) as the dimension in the figure. (M/T models)

  A : Crankshaft (rear end surface) 

  b : 10.20 - 10.85 mm (0.402 - 0.427 in) 

  [Target: 10.20 mm (0.402 in)] 

  Fig 18: Identifying Pilot Bushing

  

1. Right bank
2. Left bank

   <=: Engine front

• Install knock sensor so that connector faces rear of the engine.
• After installing knock sensor, connect harness connector, and lay it out to rear of the engine.

Flywheel  (M/T models)

• Ensure the dowel pin (1) is installed in the crankshaft.

  4 :Rear oil seal

• When installing flywheel (3) to crankshaft (2), be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole (A).
  Fig 20: Identifying Flywheel And Crankshaft

  
• There is a mating mark (B) on the clutch cover side of flywheel (4).Refer it during installation.
  1. Dowel pin
  2. Rear oil seal
  3. Crankshaft

     A :Hole

     Fig 21: Identifying Mating Mark On Clutch Cover Side Of Flywheel

     

Drive plate  (A/T models)

• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
  CAUTION: If these are not aligned correctly, engine runs roughly and "MIL" turns on.
• Install drive plate (2) and reinforcement plate (3) as shown in the figure.

  1 :Ring gear

  4 :Pilot converter

  5 :Crankshaft

  <=: Engine front

  Fig 22: Identifying Drive Plate And Reinforcement Plate

  
• Holding ring gear with the ring gear stopper [SST: KV10118600 (J-48641)].
• Tighten the mounting bolts crosswise over several times.