Repair Procedures: Reassembly

1. Install the piston pin with snap ring 2EA and check the snap ring assembly thoroughly.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.
   Fig 1: Piston Front Mark And Connecting Rod Front Mark

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1. Install the coil spring and oil ring by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown in illustration below.

Fig 2: Positioning Piston Rings

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1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
   Fig 3: Connecting Rod Bearings And Connecting Rod Cap

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Tightening torque: 

27.5 ~ 31.3 N.m (2.8 ~ 3.2 kgf.m, 20.2 ~ 23.1 lb-ft)

Fig 4: Oil Jets

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1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A).
   Fig 5: Upper Bearings

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2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 6: Thrust Bearings

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1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown in illustration below.

   Tightening torque 

   Main bearing cap bolt

   49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 90° (1 ~ 8)

   19.6 N.m (2.0 kgf.m, 14.5 lb-ft) + 120° (9 ~ 16)

   29.4 ~ 31.4 N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft) (17 ~ 24)

   NOTE:

   • Always use new main bearing cap bolts.
   • If any of the bearing cap bolts are broken or deformed, replace it.
   Fig 8: Main Bearing Cap Bolts Tightening Sequence

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   Use the SST (09221-4A000), install main bearing cap bolts.

   Fig 9: Installing Main Bearing Cap Bolts Using SST (09221-4A000)

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2. Check that the crankshaft turns smoothly.

1. 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.
2. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
3. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

   Tightening torque: 

   27.5~31.4 N.m (2.8~3.2 kgf.m, 20.3~23.1 lb-ft) + (68~72°)

   NOTE:

   • Always use new connecting rod bearing cap bolts.
   • Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
   Fig 10: Installing Ring Compressor

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   NOTE: Use SST(09221-4A000), install connecting rod bearing cap bolts.
   Fig 11: Installing Connecting Rod Bearing Cap Bolts Using SST (09221-4A000)

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Tightening torque: 

9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 12: Oil Drain Cover And Gasket

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Tightening torque: 

9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 13: Rear Oil Seal Case

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Fig 14: Identifying Sealant Applying Area On Rear Oil Seal Case

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(Refer to "REAR OIL SEAL ")

Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in illustration below.

Tightening torque: 

9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 15: Baffle Plate Bolts Tightening Sequence

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Tightening torque: 

9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 16: Oil Cover And Gasket

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Tightening torque: 

15.7 ~ 23.5 Nm (1.6 ~ 2.4 kgf.m, 11.6 ~ 17.3 lb-ft)

Fig 17: Knock Sensor

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(Refer to "DRIVE PLATE ")

(Refer to "OIL FILTER ")

(Refer to "OIL PUMP ")

(Refer to "WATER JACKET SEPARATOR ")

(Refer to "CYLINDER HEAD ")

(Refer to "WATER TEMPERATURE CONTROL ASSEMBLY ")

(Refer to "TIMING CHAIN ")

(Refer to "EXHAUST MANIFOLD ")

(Refer to "INTAKE MANIFOLD ")

(Refer to "ENGINE AND TRANSMISSION ASSEMBLY ")