13454988

1.

Assemble the piston and connecting rod.

(1)

Use a hydraulic press for installation

(2)

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 expander 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 crankshaft main bearings.

note

Upper 1, 2, 4, 5 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 oil jet (A).

Tightening torque :

8.8 ~ 12.7N.m (0.9 ~ 1.3kgf.m, 6.5 ~ 9.4lb-ft)

6.

Place the crankshaft on the cylinder block (A).

7.

Place the bed plate on the cylinder block (A).

note

●

Standard liquid gasket : FD20, HYLOMAR3000, Dreibond 5105

●

Check that the mating surfaces are clean and dry before applying liquid gasket.

●

Apply liquid gasket in a 3mm wide bead without stopping.

●

After assembly, wait at least 30 minutes before filling the engine with oil.

8.

Install the bed plate bolts.

note

●

The bed plate bolts are tightened in 2 progressive steps.

●

If any of the bed plate bolts in broken or deformed, replace it.

(1)

Apply a light coat of engine oil on the threads and under the bed plate bolts.

(2)

Tighten the bolts (11, 17, 20) in numerical order.

(3)

Tighten the main bearing cap bolts (1~10) in numerical order using the SST (09221-4A000).

(4)

Loosen the bolts (11, 17, 20).

(5)

Tighten the bolts (11~20) in numerical order.

(6)

Tighten torque of main bearing cap bolts.

Tightening torque :

Long bolts(1~10) : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 90~94°

Short bolts(11~20) : 32.4~36.3N.m (3.3~3.7kgf.m, 23.9~26.8lb-ft)

note

Always use new main bearing cap bolts.

(7)

Check that the crankshaft turns smoothly.

9.

Check the crankshaft end play.

10.

Install the piston and connecting rod assemblies.

note

Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.

(1)

Remove the connecting rod caps (A), and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.

(2)

Install the ring compressor, check that the rings are 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-crank journal alignment before pushing the piston into place.

(4)

Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts using the SST (09221-4A000).

Tightening torque :

12.7Nm (1.3kgf.m, 9.4lb-ft) + (87~93°)

note

●

Always use new connecting rod bearing cap bolts.

●

Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.

11.

Install the rear oil seal.

(1)

Apply engine oil to a new oil seal lip.

(2)

Using the SST(09214-2A100, 09231-H1100) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

12.

Install the water pipe (A).

Tightening torque :

19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

13.

Install the cylinder head. (Refer to Cylinder head in this group)

14.

Install the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group)

15.

Install the timing chain. (Refer to Timing chain in this group)

16.

Remove the engine stand.

17.

M/T : Install the fly wheel.

Tightening torque :

68.6 ~ 78.5N.m (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lb-ft)