Assembly

NOTE:
^ 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 main bearings.

NOTE: Upper bearings have an oil groove and oil holes; lower bearings do not.

(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

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

2. Install upper thrust washers.
Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
3. Place crankshaft on cylinder block.
4. Install main bearing caps and lower thrust washers.

(a) Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.

(b) Install the 5 main bearing caps in their proper locations.

NOTE: Each bearing cap has a number and front mark.

(c) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.

(d) Install and uniformly tighten the 10 bolts of the main bearing cap in several passes, in the sequence shown.
Torque: 60 Nm (44 ft. lbs.)
(e) Check that the crankshaft turns smoothly.

(f) Check the crankshaft thrust clearance.
^ Using a dial indicator, measures the thrust clearance while prying the crankshaft back and forth: with a screwdriver.
Standard thrust clearance: 0.015 - 0.220 mm (0.0006 - 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
5. Install piston and connecting rod assembles.

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.
6. Install connecting rod caps.
A. Place connecting rod cap on connecting rod.
(a) Match the numbered connecting rod cap with the connecting rod.

(b) Install the connecting rod cap with the front mark facing forward.
B. Install connecting rod cap nuts.

NOTE:
^ The cap nuts are tightened in 2 progressive steps (steps (b) and (d)).
^ If any one of the connecting rod bolts are broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.

(b) Install and alternately tighten the bolts of the connecting rod cap in several passes.
Torque: 25 Nm (18 ft. lbs.)
If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolt.

(d) Tighten the connecting rod cap bolts by an additional 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.

(g) Check connecting rod thrust clearance.
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 - 0.25 mm (0.0059 - 0.0098 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
7. Install rear oil seal retainer.
Install a new gasket and the retainer with the 6 bolts.
Torque: 9.3 Nm (82 inch lbs.)