Assembly
PISTON INSTALLATIONOIL: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
1. If the crankshaft is already installed:
- Set the crankshaft to BDC for each cylinder.
- Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
- Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
- Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
- Install the rod caps with bearings, and torque the nuts to: 46 Nm (4.7 kgf.m, 34 ft. lbs.)
2. If the crankshaft is not installed:
- Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
- Position all pistons at top dead center.
NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
CRANKSHAFT AND BALANCER SHAFT INSTALLATION
OIL: Before installing the crankshaft, apply a coat of engine oil to the main bearings, rod bearings and balancer shaft bearings.
1. Install the thrust washers in the No. 4 journal of the cylinder block.
2. Insert the bearing halves in the cylinder block and connecting rods.
3. Hold the crankshaft so the rod journals for cylinders No. 2 and No. 3 are straight up.
4. Lower the crankshaft into the block, seating the rod journals into connecting rods No. 1 and No. 4. Install the rod caps and nuts finger tight.
5. Rotate the crankshaft clockwise, seat the journals into connecting rods No. 2 and No. 3, and install the rod caps and nuts finger tight.
NOTE: Install the caps so the bearing recess is on the same side as the recess in the rod.
6. Check rod bearing clearance with plastigage, then torque the cap nuts.
46 Nm (4.7 kgf.m, 34 ft. lbs.)
NOTE: Reference numbers on the connecting rods are for big-end bore tolerance and do not indicate the position of the piston in the engine.
7. Install the main bearing caps and bearing cap bridge.
8. Check clearance with plastigage, then tighten the bearing cap bolts in two steps.
In the first step, tighten all bolts in sequence to about 29 Nm (3.0 kgf.m, 22 ft. lbs.); in the final step, tighten them in the same sequence, to 74 Nm (7.5 kgf.m, 54 ft. lbs.).
NOTE: Coat the bolt threads with engine oil
CAUTION: Whenever any crankshaft bearing or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for approximately 15 minutes.
9. Apply liquid gasket to the block mating surface of the right side cover, then install it on the cylinder block.
NOTE:
- Use liquid gasket, part No. 08718-0001 or 08718-0003.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- Apply liquid gasket evenly, being careful to cover all the mating surface.
- To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the old residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
10. Insert the balancer shafts into the block, then install the retainer to the front balancer shaft and block.
11. Apply liquid gasket to the oil pump mating surface of the block, then install the oil pump on the cylinder block.
Apply grease to the lips of the oil seals.
Then, install the oil pump while aligning the inner rotor with the crankshaft. When the pump is in place, clean any excess grease off the crankshaft and the balancer shaft, then check that the oil seal lips are not distorted.
12. Install the oil screen.
13. Hold the front balancer shaft with a screwdriver, then install the balancer belt driven pulley.
14. Before installing the balancer driven gear and the balancer gear case, apply molybdenum disulfide to the thrust surfaces of the balancer gears as shown.
15. Hold the rear balancer shaft with a 6 x 100 mm bolt, then install the balancer driven gear.
16. Install the balancer gear case to the oil pump.
NOTE: Align the groove on the pulley edge to the pointer on the gear case while holding the rear balancer with 6 x 100 mm bolt, then install the gear case.
17. Check the alignment of the pointers after installing the gear case.
18. Apply liquid gasket to the oil pan mating surface of the block, then install the oil pan on the cylinder block.
19. Tighten nuts finger-tight at six points as shown.
20. Tighten all bolts and nuts, starting from nut (1), clockwise in three steps.
NOTE: Excessive tightening can cause distortion of oil pan gasket and oil leakage.
Torque:12 Nm (1.2 kgf.m, 8.7 ft. lbs.)
CRANKSHAFT AND BALANCER SHAFT OIL SEALS INSTALLATION (ENGINE REMOVAL NOT REQUIRED)
NOTE: The crankshaft and front balancer shaft oil seal housing surface should be dry.
OIL: Apply a light coat of grease to the crankshaft, the balancer shaft and to the lips of the seals.
1. Using the special tool, drive in the crankshaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted.
2. Using the special tool, press in the front balancer shaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the balancer shaft, and check that the oil seal lip is not distorted.
3. Using the special tool, drive the crankshaft oil seal into the right side cover to the point where the clearance between the bottom of the crankshaft oil seal and right side cover is 0.5 - 0.8 mm (0.02 - 0.03 inch).
NOTE: Align the hole in the driver attachment with the pin on the crankshaft.