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Part 2

Cylinder Block (Continued)

8) Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install the rear oil seal using ST1 and ST2.

NOTE:
Use a new rear oil seal.

ST1 18671AA020 OIL SEAL GUIDE
ST2 18657AA030 OIL SEAL INSTALLER





9) Install the A/C compressor bracket bolts and the power steering pump bracket bolts at the locations shown in the figure.

NOTE:
^ This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step.
^ Use the same length bolt for the four bolts.





10) Raise the cylinder block so that the rear oil seal is on the lower side.
11) Align the ring closed gaps of piston ring and oil ring for each piston.

NOTE:
^ Make sure ring gaps do not face the same direction.
^ Check that the piston ring mark of top ring and second ring faces the top side of the piston.
^ Check that the ring gaps is not positioned within the range of piston skirt extended line.

(1) Set the ring gap of the top ring to the position (A) in the figure.





(2) Position the ring gap of second ring at (B) in the figure on the 180° opposite direction of (A).





(3) Set the ring gap of the upper rail to the position (C) in the figure.





(4) Align the upper rail spin stopper (E) to the side hole (D) on the piston.





(5) Position the ring gap of expander at (F) in the figure on the 180° opposite direction of (C).





(6) Set the ring gap of lower rail at position (G), located 120° clockwise from (C) in the figure.





12) Install the piston and connecting rod to the cylinder block.
(1) Apply engine oil to the outer circumference of each piston, crank pin, and in the cylinder block.
(2) Turn the crankshaft so that the #1 crank pin (A) is positioned at TDC using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(3) Compress the piston ring using piston ring compressor, and insert the #1 connecting rod with #1 piston into cylinder block.

CAUTION:
^ Be careful not to damage the cylinder liner and #1 crank pin by the #1 connecting rod large end.
^ Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.


NOTE:
^ Face the piston front mark (arrow) towards the front of the engine.





^ Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.





(4) Turn the crankshaft counterclockwise so that the #1 crank pin and the large end of #1 connecting rod (A) are positioned as shown in the figure using ST, while pressing the #1 piston crown, and then set the #1 connecting rod cap and #1 connecting rod cap bolt.

NOTE:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
^ Use a new connecting rod cap bolt.
^ Apply a coat of engine oil to the #1 connecting rod cap seat and the connecting rod cap bolt threads.

ST 18252AA000 CRANKSHAFT SOCKET





(5) Using ST, tighten the #1 connecting rod cap bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 Nm (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
ST 18270AA010 SOCKET





(6) Turn the crankshaft clockwise so that the #2 crank pin (A) is positioned at TDC using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(7) Compress the piston ring using piston ring compressor, and insert the #2 connecting rod with #2 piston into cylinder block.

CAUTION:
^ Be careful not to damage the cylinder liner and #2 crank pin by the #2 connecting rod large end.
^ Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.


NOTE:
^ Face the piston front mark (arrow) towards the front of the engine.





^ Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.





(8) Turn the crankshaft clockwise so that the #2 crank pin and the large end of #2 connecting rod (A) are positioned as shown in the figure using ST, while pressing the #2 piston crown, and then set the #2 connecting rod cap and #2 connecting rod cap bolt.

NOTE:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
^ Use a new connecting rod cap bolt.
^ Apply a coat of engine oil to the #2 connecting rod cap seat and the connecting rod cap bolt threads.

ST 18252AA000 CRANKSHAFT SOCKET





(9) Using ST, tighten the #2 connecting rod cap bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 Nm (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
ST 18270AA010 SOCKET





(10) Turn the crankshaft clockwise so that the #3 crank pin (A) is positioned at TDC using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(11) Compress the piston ring using piston ring compressor, and insert the #3 connecting rod with #3 piston into cylinder block.

CAUTION:
^ Be careful not to damage the cylinder liner and #3 crank pin by the #3 connecting rod large end.
^ Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.


NOTE:
^ Face the piston front mark (arrow) towards the front of the engine.





^ Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.





(12) Turn the crankshaft counterclockwise so that the #3 crank pin and the large end of #3 connecting rod (A) are positioned as shown in the figure using ST, while pressing the #3 piston crown, and then set the #3 connecting rod cap and #3 connecting rod cap bolt.

NOTE:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
^ Use a new connecting rod cap bolt.
^ Apply a coat of engine oil to the #3 connecting rod cap seat and the connecting rod cap bolt threads.

ST 18252AA000 CRANKSHAFT SOCKET





(13) Using ST, tighten the #3 connecting rod cap bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 Nm (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
ST 18270AA010 SOCKET





(14) Turn the crankshaft clockwise so that the #4 crank pin (A) is positioned at TDC using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(15) Compress the piston ring using piston ring compressor, and insert the #4 connecting rod with #4 piston into cylinder block.

CAUTION:
^ Be careful not to damage the cylinder liner and #4 crank pin by the #4 connecting rod large end.
^ Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.


NOTE:
^ Face the piston front mark (arrow) towards the front of the engine.





^ Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.





(16) Turn the crankshaft clockwise so that the #4 crank pin and the large end of #4 connecting rod (A) are positioned as shown in the figure using ST, while pressing the #4 piston crown, and then set the #4 connecting rod cap and #4 connecting rod cap bolt.

NOTE:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
^ Use a new connecting rod cap bolt.
^ Apply a coat of engine oil to the #4 connecting rod cap seat and the connecting rod cap bolt threads.

ST 18252AA000 CRANKSHAFT SOCKET





(17) Using ST, tighten the #4 connecting rod cap bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 Nm (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
ST 18270AA010 SOCKET





(18) Install the cam carrier mounting bolts at the locations shown in the figure.

NOTE:
This procedure is required to tighten the connecting rod cap bolts with specified angle using ST.





(19) Turn the crankshaft so that the #1 connecting rod cap (A) and #4 connecting rod cap (B) is located at the position shown in the figure using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(20) Using ST1 and ST2, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with specified angle in numerical order as shown in the figure.

NOTE:
Attach the magnet used for securing the ST1 (ANGLE GAUGE) to the cam carrier mounting bolt attached in step (18).

ST1 18854AA000 ANGLE GAUGE
ST2 18270AA010 SOCKET

Tightening angle:
137°±2°





(21) Turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(22) Using ST1 and ST2, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with specified angle in numerical order as shown in the figure.

NOTE:
Attach the magnet used for securing the ST1 (ANGLE GAUGE) to the cam carrier mounting bolt attached in step (18).

ST1 18854AA000 ANGLE GAUGE
ST2 18270AA010 SOCKET

Tightening angle:
137°±2°





(23) Remove the cam carrier mounting bolts attached at the locations shown in the figure.





13) Set the cylinder block so that the oil pan side is on the upper side, and remove the A/C compressor bracket bolts and the power steering pump bracket bolts attached at the locations shown in the figure.





14) Install the oil pan upper with oil pan to the cylinder block.
(1) Apply liquid gasket to the mating surface of oil pan upper as shown in the figure.

NOTE:
^ Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block and the oil pan upper.
^ Install within 5 min. after applying liquid gasket.
^ Apply liquid gasket 1.5 mm (0.0591 in) outside from the chamfer surface. However, application of liquid gasket on the chamfer surface around the bolt hole is allowed.

Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:
5±1 mm (0.1969±0.0394 in)





(2) Install the O-ring to the cylinder block.

NOTE:
Use new O-rings.





(3) Set the oil pan with oil pan upper to the cylinder block, and tighten the bolts in numerical order as shown in the figure.

NOTE:
After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.

Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)





15) Set the thermostat to the oil pan upper, and install the thermostat cover.

NOTE:
Use a new gasket.

Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)





16) Install the ST1, ST2, ST3 and ST4 to the cylinder block and oil pan upper.

ST1 498457000 ENGINE STAND ADAPTER RH
ST2 498457100 ENGINE STAND ADAPTER LH
ST3 18362AA020 ADAPTER
ST4 499817100 ENGINE STAND

Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)





17) Install the crankshaft position sensor with crankshaft position sensor holder to the cylinder block LH.

Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)





18) Install the crankshaft position sensor plate with drive plate. (AT model)
19) Install the crankshaft position sensor plate with flywheel. (MT model)