INSTALLATION
| INSTALLATION |
|
(1)
|
Crankshaft
bearing
|
(3)
|
Cylinder
block
|
(4)
|
Rear oil
seal
|
|
(2)
|
Crankshaft
|
Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
Position the crankshaft on #2 and #4 cylinder block.
Apply liquid gasket to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.
Liquid gasket:
Part No. 32005013
THREE BOND 1215 or equivalent| Note | ||
|
Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. |
Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side)
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side)
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
Tighten the LH side bolts (A — D) in alphabetical sequence.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tighten the RH side bolts (A — D) in alphabetical sequence.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Further tighten the LH side bolts (A — D) to 90° in alphabetical sequence.
Further tighten the RH side bolts (E — J) to 90° in alphabetical sequence.
Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure.
Tightening torque:
(A) — (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Install the rear oil seal using ST1 and ST2.
ST1 32005141 CRANKSHAFT OIL SEAL GUIDE
ST2 32005136 CRANKSHAFT OIL SEAL INSTALLER
|
(A)
|
Rear oil
seal
|
|
(B)
|
Flywheel
attaching bolt
|
Position the top ring gap at (A) or (B) in the figure.
Position the second ring gap at 180° on the reverse side for the top ring gap.
Position the expander gap at (C) in the figure.
Position the lower rail gap at (D) in the figure.
Align lower rail spin stopper (F) with piston side surface hole (E).
Position the upper rail gap at (G) in the figure.
| Important | ||
| • |
Ensure ring gaps do not face
the same direction.
|
|
| • |
Ensure ring gaps are not within the piston skirt area.
|
|
Install the snap ring.
Install the snap rings in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders.
| Note | ||
|
Use new snap rings. |
|
(1)
|
Piston
|
(4)
|
Gasket
|
Tightening torque: Nm (kgf-m, ft-lb)
|
|
|
(2)
|
Piston
pin
|
(5)
|
Service
hole plug
|
T:
|
70 (7.1, 51.4)
|
|
(3)
|
Snap ring
|
||||
Installing the piston:
Turn the cylinder block so that #1 and #2 cylinders face upward.
Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
ST1 32005170 CRANKSHAFT SOCKET
Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.ST2 32005076 PISTON GUIDE
| Note | ||
|
Piston front mark faces towards the front of the engine. |
|
(A)
|
Front mark
|
Installing piston pin:
Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end.
ST3 32005121 PISTON PIN GUIDE
Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole.
Install the snap ring.
| Note | ||
|
Use new snap rings. |
Apply liquid gasket around the service hole plug.
Liquid gasket:
Part No. 32005013
THREE BOND 1215 or equivalent
Install the service hole plug and gasket.
| Note | ||
|
Use a new gasket. |
|
(1)
|
Piston
|
(5)
|
Service
hole plug
|
Tightening torque: Nm (kgf-m, ft-lb)
|
|
|
(2)
|
Piston
pin
|
(6)
|
Service
hole cover
|
T1:
|
6.4 (0.65, 4.7)
|
|
(3)
|
Snap ring
|
(7)
|
O-ring
|
T2:
|
70 (7.1, 51.4)
|
|
(4)
|
Gasket
|
||||
Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
Install the water pipe.
Install the baffle plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Install the oil strainer and O-ring
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
Install the oil strainer stay.
Apply liquid gasket to the matching surfaces, and then install the oil pan.
Liquid gasket:
Part No. 32005015
THREE BOND 1207C or equivalent
Apply liquid gasket to the matching surfaces, and then install the oil separator cover.
Liquid gasket:
Part No. 32005015
THREE BOND 1207C or equivalent
Install the drive plate. (AT model)
To lock the crankshaft, use ST.
ST 32005107 CRANKSHAFT STOPPER
Tightening torque:72 Nm (7.3 kgf-m, 52.8 ft-lb)
Install the flywheel. (MT model)
Install the clutch disc and cover. (MT model)
Installation of oil pump:
Discard the front oil seal after removal. Replace with a new one using the ST.
ST 32005135 OIL SEAL INSTALLER
Apply liquid gasket to the matching surface of oil pump.
Liquid gasket:
Part No. 32005013
THREE BOND 1215 or equivalent
|
(A)
|
O-ring
|
Apply a coat of engine oil to the inside of the oil seal.
Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
| Important | ||
| • |
Do not forget to install the
O-ring and seal when installing the oil pump.
|
|
| • |
Align the flat surface of oil pump’s inner
rotor with crankshaft before installation.
|
|
Install the water pump and gasket.
Tightening torque:
First; 12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second; 12 Nm (1.2 kgf-m, 8.7 ft-lb)
| Important | ||
| • |
Be sure to use a new gasket.
|
|
| • |
When installing the water pump, tighten the bolts in
two stages in alphabetical sequence as shown in the figure.
|
|
Install the water by-pass pipe for heater.
Install the oil cooler.
Tightening torque:
T1: 54 Nm (5.5 kgf-m, 40 ft-lb)
T2: 69 Nm (7.0 kgf-m, 50.6 ft-lb)
|
(A)
|
O-ring
|
|
(B)
|
Oil cooler
|
|
(C)
|
Oil cooler
connector
|
Install the oil filter using ST.
ST 32005021 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in))
Install the oil filter by turning it by hand, being careful not to damage the seal rubber.Tighten the oil filter 68 mm (2.68 in) in diameter by approx. 1 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler.
| Important | ||
|
Do not tighten excessively, or oil may leak. |
||
Install the water by-pass pipe between oil cooler and water pump.
Install the water pipe.
| Note | ||
|
Always use a new O-ring. |
Install the cylinder head assembly.
Install the oil level gauge guide and tighten the attaching bolt (LH side).
Install the rocker cover and rocker cover gasket.
| Note | ||
|
Use new rocker cover gasket. |
Install the crank sprocket.
Install the cam sprocket.
Install the timing belt assembly.
Install the timing belt cover.
Install the crank pulley.
Install the generator and A/C compressor brackets on cylinder head.
Install the V-belt.
Install the intake manifold.
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