Engine Mechanical Cylinder Block: Reassembly

1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.
   Fig 1: Installing Snap Ring On One Side Oil Piston Pin Hole

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2. Gradually heat the piston to about 60°C (140°F).
   Fig 2: Heating Piston

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3. Coat the piston pin with engine oil.
4. Position the piston front mark to the outside mark on the connecting rod as shown in the diagram.
   NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R".
   Fig 3: Positioning Front Mark To Outside Mark On Connecting Rod

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5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
6. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
   Fig 4: Installing Snap Ring On Other Side of Piston Pinhole

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1. Install the oil ring expander and the 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
   Fig 5: Installing Compression Rings With Code Mark

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   CODE MARK
   
   

   Ring Number	Mark
   No.1	1R
   No2.	2R

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 the connecting cap.
2. Install the bearings in the connecting rod and the connecting rod cap.

Fig 7: Aligning Bearing Claw With Groove Of Connecting Rod

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Fig 8: Identifying Main Bearing

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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 9: Aligning Bearing Claw With Claw Groove Of Cylinder Block

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2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

Fig 10: Aligning Bearing Claw With Claw Groove Of Main Bearing Cap

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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.

Fig 11: Installing Thrust Washers Under No. 3 Journal Position

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1. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
   Fig 12: Installing Thrust Washer On No. 3 Bearing Cap

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2. Install the 5 main bearing caps in their proper locations.
   Fig 13: Installing 5 Main Bearing Caps In Proper Locations

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1. Apply a light coat of engine oil on the threads and under the main bearing cap bolts.
2. Install and evenly tighten the 10 main bearing cap bolts a little at a time for several times as in the sequence shown.
   1. Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 

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

   Fig 14: Tightening Main Bearing Cap Bolts In Sequence

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3. Mark the front of the main bearing cap bolt with paint.
4. Retighten the main bearing cap bolts by 90° in the numerical order shown.
   Fig 15: Retightening Main Bearing Cap Bolts An Additional 90°

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5. Check that the painted mark is now at a 90° angle to the front.
6. 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 16: Installing Piston & Connecting Rod Assembly

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Fig 17: 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 groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
3. Check that the outside mark of the connecting rod cap is facing in correct direction.
   Fig 18: Checking Outside Mark Of Connecting Rod

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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 a little at a time for several times.
   1. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 
   Fig 19: Tightening Connecting Rod Cap Bolts Alternating

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   If any one 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 bolt with paint.
   Fig 20: Marking Front Of Connecting Cap Bolt With Paint

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4. Retighten the cap bolts 90° as shown.
5. Check that the painted mark is now at a 90° angle to the front.
6. 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 oil seal retainer and the cylinder block.
   • Using a razor blade and a gasket scraper, remove old FIPG from the seal surface.
   • Clean all the components to remove the redundant FIPG completely.
   • Clean sealing surfaces with solvent so that any residue does not remain on the seal.
2. Apply seal packing to the oil seal retainer as shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
      • Install a nozzle that is cut to a 2 - 3 mm (0.08-0.12 in.) opening.
      • Parts must be assembled within 5 minutes after the seal packing application. Otherwise the material must be removed and the seal packing have to be reapplied.
      • Immediately remove the nozzle from the tube and reinstall the cap.
   Fig 21: Applying Seal Packing To Oil Seal Retainer

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3. Install a new O-ring to the cylinder block.
4. Install the oil seal retainer with the 7 bolts.
   1. Torque: 8.0 N.m (80 kgf.cm, 71 in..lbf) 
   Fig 22: Installing Oil Seal Retainer

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1. Apply seal packing to 2 or 3 threads from the end of the drain unions.
   1. Seal packing: Part No. 08826-00100 or equivalent 
   Fig 23: Applying Seal Packing From End Of Drain Unions

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2. Install the 2 drain unions.
   1. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 
      Fig 24: Installing Drain Unions

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   NOTE: After applying the specified torque, rotate the drain union clockwise until the drain port is facing forward.

Install the mounting bracket with the 4 bolts. Install the 2 mounting brackets.

1. Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

1. Install the bracket on the engine wire with the bolt.
   Fig 25: Installing Bracket On Engine Wire (LH)

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2. Install the engine wire cover with the 2 bolts.

Install the 2 brackets on the engine wire with the 2 bolts.

Fig 26: Installing Bracket On Engine Wire (RH)

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Install the bracket with the bolt.

1. Install a new O-ring to the water bypass pipe.
2. Apply soapy water to the O-ring.
3. Push the water bypass pipe end into the pipe hole of the water pump.
4. Install the water bypass pipe with the bolt.
   1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
   Fig 27: Installing Water Bypass Pipe

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5. Install the wire clamp to the bracket of the water bypass pipe.