Engine Unit: Reassembly

HINT:

• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.

1. INSTALL STUD BOLT 
   Fig 1: Installing Stud Bolt

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2. INSTALL STRAIGHT PIN 
   Fig 2: Installing Straight Pin

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3. INSTALL RING PIN 
   Fig 3: Installing Ring Pin

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4. INSTALL PISTON SUB-ASSEMBLY WITH PIN 
   1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.
      Fig 4: Installing Snap Ring On Piston Pin Hole

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   2. Gradually heat the piston to about 60°C (140°F).
      Fig 5: Heating Piston

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   3. Coat the piston pin with engine oil.
   4. The piston's front mark and the connecting rod's outside mark should face the same direction, as shown in Fig 6.
      NOTE: The installation directions of the piston and connecting rod are different for the bank 1 and bank 2. The bank 1 piston is marked with 1 cavity and "LH", the bank 2 piston with 2 cavities and "RH".
      Fig 6: Aligning Holes Of Piston & Connecting Rod

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   5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
   6. Check the fit between the piston and piston pin.
      1. Try to move the piston back and forth on the piston pin.
         Fig 7: Checking Fit Between Piston & Piston Pin

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   7. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
      Fig 8: Installing Snap Ring On Other Side Of Piston Pin Hole

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   8. Install the oil ring expander and 2 side rails by hand.
   9. Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.
      Fig 9: Installing No. 1 & 2 Piston Rings

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      Code mark 

      PISTON RING CODE MARK
      
      

      Piston Ring	Code Mark
      No. 1	None
      No. 2	2R

   10. Position the piston rings so that the ring ends are as shown in Fig 10.
       Fig 10: Positioning Piston Rings

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       NOTE: Do not align the ring ends.
5. INSTALL CONNECTING ROD BEARING 
   1. Align the bearing claw with the groove of the connecting rod or connecting cap.
   2. Install the bearings in the connecting rod and connecting rod cap.
      Fig 11: Installing Connecting Rod Bearing

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6. INSTALL CRANKSHAFT BEARING 

   HINT:

   • Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
   • Upper bearings have an oil groove and oil holes; lower bearings do not.
     Fig 12: Identifying Main Bearings

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   1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
      Fig 13: Aligning Bearing Claw With Claw Groove Of Cylinder Block

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   2. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

      HINT:

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

      Fig 14: Aligning Bearing Claw With Claw Groove Of Crankshaft Bearing Cap

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7. INSTALL CRANKSHAFT THRUST WASHER SET 
   1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
      Fig 15: Installing Thrust Washers Under No. 3 Journal Position

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   2. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
      Fig 16: Installing Thrust Washers On Bearing Cap With Grooves

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8. INSTALL CRANKSHAFT 
   1. Place the crankshaft on the cylinder block.
   2. Install the 5 crankshaft bearing caps in their proper locations.

      HINT:

      Place the bearing caps on the level and let them return to their original positions by their own weight.

      NOTE: Do not install the bearing cap by tapping it.
      Fig 17: Installing Crankshaft Bearing Caps

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   3. Install the crankshaft bearing cap bolts.

      HINT:

      If any one of the bearing cap bolts is broken or deformed, replace it.

      1. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
      2. Install and uniformly tighten the 10 crankshaft bearing cap bolts in several passes in the sequence shown in Fig 18.

         Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

         If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.

         Fig 18: Installing Crankshaft Bearing Caps Bolts In Sequence

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      3. Mark the front of the crankshaft bearing cap bolt's head with paint.
      4. Tighten the crankshaft bearing cap bolts another 90° as shown in Fig 19 .
      5. Check that the painted mark is now at a 90° angle to the front.
   4. Check that the crankshaft turns smoothly.
9. CHECK CRANKSHAFT THRUST CLEARANCE (See  DISASSEMBLY   ) 
   Fig 19: Tightening Crankshaft Bearing Caps Bolts

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10. INSTALL PISTON AND CONNECTING ROD 
    1. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
       NOTE: The shape of the piston varies for the bank 1 and bank 2. The bank 1 piston is marked with 1 cavity and "LH" the bank 2 piston with 2 cavities and "RH".
       Fig 20: Pushing Piston & Connecting Rod Cylinder

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    2. Place the connecting rod cap on the connecting rod.
       1. Match the numbered connecting rod cap with the connecting rod.
       2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
          Fig 21: Placing Connecting Rod Cap On Connecting Rod

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       3. Check that the outside mark of the connecting rod cap is facing in the correct direction.
          Fig 22: Checking Outside Mark Of Connecting Rod Cap

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    3. Install the connecting rod cap bolts.

       HINT:

       If any one of the connecting rod cap bolts is broken or deformed, replace it.

       1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
       2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.

          Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

          If any of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.

          Fig 23: Installing Connecting Rod Cap Bolts

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       3. Mark the front of the connecting cap bolt with paint.
       4. Tighten the cap bolts another 90° as shown in Fig 24 .
       5. Check that the painted mark is now at a 90° angle to the front.
       Fig 24: Tightening Connecting Rod Cap Bolts

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    4. Check that the crankshaft turns smoothly.
11. CHECK CONNECTING ROD THRUST CLEARANCE (See  REASSEMBLY   ) 
12. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply seal packing to 2 or 3 threads of the drain cocks.

       Seal packing: Part No. 08826-00100 or equivalent 

       Fig 25: Applying Seal Packing To Threads Of Drain Cocks

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    2. Install the 2 drain cocks.

       Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

       HINT:

       After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

    Fig 26: Installing Drain Cocks

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13. INSTALL REAR OIL SEAL RETAINER 
    1. Remove any old packing (FIPG) material, and be careful not to drop any oil on the contact surfaces of the oil seal retainer and the cylinder block.
       1. Using a razor blade and a gasket scraper, remove old FIPG from the seal surface.
       2. Clean all the components to remove the redundant FIPG completely.
       3. Clean sealing surfaces with solvent so that any residue does not remain on the seal.
    2. Apply seal packing to the oil seal retainer as shown in Fig 27.
       • Seal packing: Part No. 08826-00080 or equivalent 
       • Standard seal diameter: 3 to 4.5 mm (0.12 to 0.18 in.) 
       NOTE:

       • Remove any oil from the contact surface.
       • Install the oil seal within 3 minutes after applying seal packing.
       • Do not start the engine for at least an hour after installing the oil seal retainer.
       Fig 27: Applying Seal Packing To Oil Seal Retainer

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    3. Install a new O-ring to the cylinder block.
    4. Install the oil seal retainer with the 7 bolts.

       Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    Fig 28: Installing Oil Seal Retainer

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14. INSTALL OIL PUMP ASSEMBLY (See  INSTALLATION  ) 
15. INSTALL OIL STRAINER SUB-ASSEMBLY (See  INSTALLATION  ) 
16. INSTALL OIL PAN STUD BOLT 
    Fig 29: Installing Oil Pan Stud Bolt

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17. INSTALL OIL PAN SUB-ASSEMBLY (See  INSTALLATION  ) 
18. INSTALL OIL PAN BAFFLE PLATE (See  INSTALLATION  ) 
19. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See  INSTALLATION  ) 
20. INSTALL WATER PUMP ASSEMBLY (See  INSTALLATION  ) 
21. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    1. Install the cylinder head (see INSTALLATION  ).
22. INSTALL CRANKSHAFT TIMING PULLEY 
    1. Fit the timing pulley set key to the key groove of the pulley.
    2. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.

       SST 09223-46011 

       Fig 30: Tapping In Timing Pulley Using SST & Hammer

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23. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY 
    1. Install the idler with the bolt.

       Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf) 

    2. Check that the idler moves smoothly.
       Fig 31: Installing No. 2 Timing Belt Idler Sub-Assembly

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24. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the pivot bolt.

       Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCATE 242 or equivalent 

       Fig 32: Applying Adhesive To Threads Of Pivot Bolt

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    2. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.

       Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf) 

    3. Check that the idler bracket moves smoothly.
25. INSTALL TIMING BELT 
    1. Install the timing belt (see INSTALLATION  ).