Cylinder Block: Reassembly

1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
   NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
   Fig 1: Installing First Piston Pin Snap Ring

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2. Gradually heat the piston to 80 - 90°C (176 - 194°F).
   Fig 2: Heating Pistons To Install Piston Pin

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3. Coat the piston pin with engine oil.
4. Align the front marks on the piston and connecting rod, and push in the piston with your thumb.
   Fig 3: Aligning Piston & Connecting Rod Marks

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5. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
   NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.
   Fig 4: Installing Second Piston Pin Snap Ring

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1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

   Code mark (No. 2 only): T or 2R 

   Fig 5: Using Piston Ring Expander To Install Rings

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3. Position the piston rings so that the ring ends are as shown.
   Fig 6: Positioning Piston Rings

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   NOTE: Do not align the ring ends.

1. Align the bearing claw with the groove of the connecting rod or connecting cap.
2. Install the bearings in the connecting rod and connecting rod cap.
   Fig 7: Installing Bearing Shell Into Connecting Rod

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1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
   NOTE:

   • Install the bearing with the oil hole in the cylinder block.
     Fig 8: Installing Main Bearing Shell Into Cylinder Block

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   • Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
   Fig 9: Installing Main Bearing Shells Into Main Bearing Cap

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   NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.

Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 10: Installing Thrust Washers

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1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap subassembly and cylinder block.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-reusable solvent, clean both sealing surfaces.
2. Apply seal packing to the bearing cap subassembly.
   Fig 11: Identifying Locations For Applying Seal Packing

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   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to an 1 - 2 mm (0.004 - 0.08 in.) opening.
     NOTE: Avoid applying an excessive amount to the surface.
   • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove the nozzle from the tube and reinstall cap.
3. Using a plastic-faced hammer, lightly tap the bearing cap subassembly to ensure a proper fit.
   Fig 12: Using Plastic Hammer To Tap Bearing Cap Assembly Into Place

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1. Apply a light coat of engine oil on the threads and under the bearing cap subassembly bolts.
2. Install and uniformly tighten the 10 bearing cap subassembly bolts in several passes.
   Fig 13: Identifying Bearing Cap Subassembly Bolt Tightening Sequence

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   Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) 

3. Tighten the bearing cap subassembly bolts in several passes. See Fig 13.

   Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) 

   If any of the bearing cap subassembly bolts does not meet the torque specification, replace the bearing cap subassembly bolt.

4. Mark the front of the bearing cap subassembly bolts with paint.
   Fig 14: Tightening Painted Bolts In 45 Degree Increments

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5. Retighten the bearing cap subassembly bolts by 45 degrees and additional 45 degrees in the numerical order shown.
6. Check that the painted mark is now at a 90 degree angle to the front.

1. Install and uniformly tighten the 10 bearing cap subassembly bolts in several passes.

   Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) 

2. Check that the crankshaft turns smoothly.

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.

Fig 15: Installing Piston/Connecting Rod Assemblies

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1. Match the numbered connecting rod cap with the connecting rod.
2. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
   Fig 16: Placing Connecting Rod Cap On Connecting Rod

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   NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and do not let the oils and fats stick.
3. Check that the protrusion of the connecting rod cap is facing in the correct direction.
   Fig 17: Confirming Connecting Rod Cap Is Installed Correctly

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1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.
   Fig 18: Tightening Connecting Rod Bearing Cap Bolts

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   Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

   If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

3. Mark the front of the connecting cap bolts with paint.
Fig 19: Tightening Painted Bolts An Additional 90 Degrees
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4. Retighten the cap bolts by 90 degrees as shown.
5. Check that the painted mark is now at a 90 degree angle to the front.
6. Check that the crankshaft turns smoothly.

Install a new gasket and the oil strainer with the 2 nuts and bolt.

Fig 20: Installing Oil Strainer

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Torque: 9 N.m (92 kgf.cm, 80 in.lbf) 

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
   NOTE: Do not use a solvent which will affect the painted surfaces.
2. Apply seal packing to the oil pan as shown.
   Fig 21: Applying Seal Packing To Oil Pan

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   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.
     NOTE: Avoid applying an excessive amount to the surface.
   • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove the nozzle from the tube and reinstall the cap.
3. Install the oil pan with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
   Fig 22: Locating Oil Pan Fasteners

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   Torque: 9 N.m (92 kgf.cm, 80 in.lbf) 

Torque: 30 N.m (306 kgf.cm, 21 ft.lbf) 

1. Apply adhesive to 2 or 3 threads.
   Fig 23: Applying Adhesive To Threads

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   Adhesive: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. Install the drain union.

   Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

   HINT:

   After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

Fig 24: Installing Water Bypass Pipe

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Torque: 9 N.m (92 kgf.cm, 80 in.lbf)