Engine Mechanical Cylinder Block: Reassembly

1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
   Fig 1: Installing Snap Ring Using A Small Screwdriver

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   NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to 80 - 90°C (176 - 194°F).
   Fig 2: Heating Piston

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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 Front Marks On Piston & Connecting Rod

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5. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
Fig 4: Installing Snap Ring On Other End Of Piston Pin Hole Using A Small Screwdriver
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Fig 5: Identifying Piston Ring Code Mark

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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.
   PISTON RING CODE MARK SPECIFICATIONS
   
   

   No. 1	None
   No. 2	T

3. Position the piston rings so that the ring ends are as shown.
Fig 6: Identifying Ring Ends Installed Position
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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 Bearings In 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.
   Fig 8: Aligning Bearing Claw With Cylinder Block Claw Groove

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   NOTE:

   • Install the bearing with the oil hole in the cylinder block.
   • 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: Aligning Bearing Claw With Main Bearing Cap Claw Groove
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Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

1. Install the 5 main bearing caps in their proper locations.
   NOTE: A number is marked on each main bearing cap to indicate the installation position.
   Fig 11: Installing Main Bearing Caps

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2. Install the main bearing cap bolts.
   Fig 12: Installing Main Bearing Caps Bolts

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   NOTE:

   • The main bearing cap bolts are tightened in 2 progressive steps (steps (2), (3) and (5)).
   • If any one of the main bearing cap bolts is broken or deformed, replace it.
   1. Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
   2. Install and uniformly tighten the 10 main bearing cap bolts in several passes, in the sequence shown.
      1. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 
   3. Retighten the 10 main bearing cap bolts in several passes, in the sequence shown.
      1. Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 

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

   4. Mark the front of the main bearing cap bolt with paint.
   5. Retighten the main bearing cap bolts by 90° in the numerical order shown.
   6. Check that the painted mark is now at a 90° angle to the front.
   Fig 13: Identifying Main Bearing Cap Bolts Painted Mark Position
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3. 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 14: Installing Piston & Connecting Rod Assemblies Using A Piston Ring Compressor

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1. Place the connecting rod cap on the connecting rod.
   Fig 15: Placing Connecting Rod Cap On Connecting Rod

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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.
      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.
2. Install the connecting rod cap bolts.
   Fig 16: Identifying Connecting Rod Cap Protrusion

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   NOTE:

   • The connecting rod cap bolts are tightened in 2 steps (steps (3) and (4)).
   • If any of the connecting rod cap bolts is broken or deformed, replace it.
   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 17: Installing & Tightening Connecting Rod Cap Bolts

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      1. Torque: 24.5 N.m (250 kgf.cm, 18 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.
   4. Retighten the cap bolts by 90° as shown.
   5. Check that the painted mark is now at a 90° angle to the front.
3. Check that the crankshaft turns smoothly.

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the crank case and cylinder block.
   Fig 19: Identifying Crank Case & Cylinder Block Old Packing

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   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
2. Apply seal packing to the crank case or cylinder block as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 2.5 - 3.0 mm (0.10 - 0.12 in.) opening.
   • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove nozzle from the tube and reinstall cap.
3. Install a new O-ring to the cylinder block.
   Fig 20: Installing O-Ring To Cylinder Block

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4. Temporarily install the crank case with the 11 bolts.
   Fig 21: Installing Crank Case Bolts

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   NOTE: Bolt length:

   112 mm (4.41 in.) for A of 12 mm head

   35 mm (1.38 in.) for B of 12 mm head

5. Uniformly tighten the bolts, stud bolts and nuts in several passes.
   1. Torque: 32.5 N.m (330 kgf.cm, 24 ft.lbf) 

Using a 12 mm hexagon wrench, install the oil filter union.

Fig 22: Installing Oil Filter Union

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1. Torque: 29.5 N.m (300 kgf.cm, 22 ft.lbf) 

Install a new gasket, the water bypass pipe with the 2 nuts.

Fig 23: Installing Water By-Pass Pipe

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1. Torque: 9 N.m (90 kgf.cm, 80 in..lbf) 

1. Install a new O-ring to the dipstick guide.
2. Apply soapy water to the O-ring.
3. Push in the dipstick guide end into the guide hole of the No. 1 oil pan.
4. Install the dipstick guide with the bolt.
   Fig 24: Installing Oil Dipstick & Guide

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   1. Torque: 9 N.m (90 kgf.cm, 80 in..lbf) 
5. Install the dipstick.

1. Apply adhesive to 2 or 3 threads.
   Fig 25: Applying Adhesive To Engine Coolant Drain Union Bolts Threads

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   Seal packing: Part No. 08826-00100 or equivalent 

2. Install the drain union.

1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) or more 

Using a 12 mm hexagon wrench, install the OCV filter with a new gasket and the plug.

Fig 26: Installing OCV Filter

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1. Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)