Assembly/Installation
INSTALLATION1. Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankshaft.
CAUTION: Install a piece of hose over threads of rod bolts. This is to prevent damage to bearing journal, cylinder walls or rod bolt threads when installing the connecting rod. Remove hose after connecting rod is in place.
2. When installing piston assembly into cylinder bore, point the arrow mark on piston head to crankshaft timing pulley side.
3. Upper connecting rod bearing to connecting rod.
4. Piston assembly into cylinder bore. Guide the connecting rod into place on the crankshaft. Install a Ring Compressor, ensuring it sits firmly against the cylinder block until all piston rings have entered the cylinder bore. Using a hammer handle, gently tap the piston head to install the piston into the bore.
5. Lower connecting rod bearing to connecting rod cap.
6. Connecting rod cap to connecting rod; secure with two connecting rod cap nuts. Tighten connecting rod cap nuts to 35 Nm (26 ft. lbs.).
7. Cylinder head gasket. Install new cylinder head gasket as shown with the TOP mark facing up (toward cylinder head) and on crankshaft timing pulley side.
8. Cylinder head; secure with ten cylinder head bolts after applying engine oil to each bolt.
9. Rubber seal between coolant pump and cylinder head.
10. Timing belt and belt tensioner.
11. Distributor to cylinder head. See Powertrain Management.
12. Throttle body and intake manifold.
13. Exhaust manifold. See Exhaust System.
14. Cylinder head cover; secure with four new seal washers and nuts. Tighten cylinder head cover nuts to 5 Nm (44 inch lbs.).
15. Oil pump strainer and engine oil pan.
16. Engine oil drain plug gasket and drain plug. Tighten engine oil drain plug to 35 Nm (26 ft. lbs.).
17. Negative (-) battery cable.
18. Refill engine oil to specifications
19. Upon completion of installation, start engine and check exhaust system for exhaust leaks. After completing that inspection, check engine oil pressure by running engine.