|
(1) |
Crankshaft bearing |
(4) |
Rear oil seal |
(7) |
Washer |
|
(2) |
Crankshaft |
(5) |
O-ring |
||
|
(3) |
Cylinder block |
(6) |
Seal washer |
1. Remove oil on the mating surface of cylinder block before installation. Apply engine oil on bearings and crankshaft journals.
2. Position the crankshaft and O-rings on #1 and #3 cylinder block.
3. Apply liquid gasket to the mating surface of #1 and #3 cylinder blocks, and position it on cylinder block #2 and #4.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
NOTE:
Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
4. Apply a coat of engine oil to the washer and bolt thread.
NOTE:
Use a new seal washer.
5. Tighten the 10 mm cylinder block connecting bolts on LH side (A — D) in alphabetical sequence.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
6. Tighten the 10 mm cylinder block connecting bolts on RH side (E — J) in alphabetical sequence.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
7. Tighten the LH side cylinder block connecting bolts (A — D) further in alphabetical order.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
8. Tighten the RH side cylinder block connecting bolts (E — J) further in alphabetical order.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
9. Tighten the LH side cylinder block connecting bolts (A — D) further in alphabetical order.
• (A), (C): Angle tightening
Tightening angle:
90°
• (B), (D): Torque tightening
Tightening torque:
40 N·m (4.1 kgf-m, 29.6 ft-lb)
10. Tighten the cylinder block connecting bolts on RH side (E — J) in alphabetical sequence.
Tightening angle:
90°
11. Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A — H) in alphabetical order.
Tightening torque:
(A) — (G): 25 N·m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
12. Apply a coat of engine oil to the periphery of oils seal and install the rear oil seals using ST1 and ST2.
NOTE:
Use a new rear oil seal.
| ST1 499597100 | CRANKSHAFT OIL SEAL GUIDE |
| ST2 499587200 | CRANKSHAFT OIL SEAL INSTALLER |
|
(A) |
Rear oil seal |
|
(B) |
Flywheel attaching bolt |
13. Position the top ring gap at (A) or (B) in the figure.
14. Position the second ring gap at 180° on the reverse side the top ring gap.
15. Position the upper rail gap at (C) in the figure.
16. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
17. Position the expander gap at (F) in the figure.
18. Position the lower rail gap at (G) in the figure.
NOTE:
• Make sure ring gaps do not face the same direction.
• Make sure ring gaps are not within the piston skirt area.
19. Install the snap ring.
Install the snap rings in the piston holes located opposite to the service holes in cylinder block before positioning all pistons in corresponding cylinders.
NOTE:
Use new snap rings.
|
(A) |
Front side |
|
(1) |
Piston |
(4) |
Gasket |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(2) |
Piston pin |
(5) |
Service hole plug |
T: |
70 (7.1, 51.4) |
|
(3) |
Snap ring |
||||
20. Installing piston:
(1) Place the cylinder block with the #1 and #2 cylinders facing upward.
(2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
| ST1 499987500 | CRANKSHAFT SOCKET |
(3) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.
| ST2 398744300 | PISTON GUIDE (DOHC NON-TURBO MODEL) |
| ST2 498747300 | PISTON GUIDE (DOHC TURBO MODEL) |
NOTE:
Face the piston front mark towards the front of the engine.
|
(A) |
Front mark |
21. Installing piston pin:
(1) Apply a coat of engine oil to ST3.
(2) Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end.
| ST3 499017100 | PISTON PIN GUIDE |
(3) Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
(4) Install the snap ring using long-nose pliers.
NOTE:
Use new snap rings.
(5) Apply liquid gasket around the service hole plug.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or equivalent
(6) Install the service hole plug and gasket.
NOTE:
Use a new gasket.
|
(1) |
Piston |
(5) |
Service hole plug |
Tightening torque:N·m (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 |
||||
(7) Place the cylinder block with cylinders #3 and #4 facing upward. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
22. Install the water pipe.
23. Install the baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
24. Install the oil strainer and O-ring.
NOTE:
Use new O-rings.
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
25. Install the oil strainer stay.
NOTE:
Tighten the oil strainer stay and baffle plate together.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
26. Apply liquid gasket to the mating surfaces, and install the oil pan.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1207C (Part No. 004403012) or equivalent
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
27. Apply liquid gasket to the mating surfaces and the threaded portion of bolt (A) shown in the figure (when bolt is reused), and then install the oil separator cover.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
Mating surface
THREE BOND 1217G or equivalent
Threaded portion of bolt (A) (when bolt is reused)
THREE BOND 1324 (Part No. 004403042) or equivalent
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
28. Install the drive plate. (AT model)
To lock the crankshaft, use ST.
| ST 498497100 | CRANKSHAFT STOPPER |
Tightening torque:
72 N·m (7.3 kgf-m, 53.1 ft-lb)
29. Install the flywheel. (MT model) 
30. Install the clutch disc and cover. (MT model)
31. Installation of oil pump:
(1) Using the ST, install the front oil seal.
| ST 499587100 | OIL SEAL INSTALLER |
NOTE:
Use a new front oil seal.
(2) Apply liquid gasket to the matching surface of oil pump.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
|
(A) |
O-ring |
(3) Apply a coat of engine oil to the inside of oil seal.
(4) Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation.
NOTE:
• Make sure the oil seal lip is not folded.
• Align the flat surface of oil pump’s inner rotor with crankshaft before installation.
• Use new O-rings and oil seals when installing the oil pump.
(5) Apply liquid gasket to the threaded portion of bolts when reusing the three bolts shown in the figure.
Liquid gasket:
THREE BOND 1324 (Part No. 004403042) or equivalent
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
32. Install the service hole plug and gasket.
Tightening torque:
First: 12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second: 12 N·m (1.2 kgf-m, 8.7 ft-lb)
NOTE:
• When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure.
• Use a new gasket.
33. Install the water by-pass pipe for heater.
34. Install the oil cooler. (Models with oil cooler)
35. Install the oil filter.
36. Install the oil filter by turning it by hand, being careful not to damage the seal rubber.
• Tighten oil filters with an outer diameter of 68 mm (2.68 in) by approx. 1 rotation after the seal rubber of the oil filter comes in contact with oil cooler. When using a torque wrench, tighten to 14 N·m (1.4 kgf-m, 10.3 ft-lb).
• Tighten oil filters with an outer diameter of 65 mm (2.56 in) by approx. 2/3 — 3/4 rotation after the seal rubber of the oil filter comes in contact with oil cooler. When using a torque wrench, tighten to 12 N·m (1.2 kgf-m, 9.8 ft-lb).
CAUTION:
Do not tighten excessively, or oil may leak.
37. Install the water by-pass pipe between oil cooler and water pump. Models with oil cooler
38. Install the water pipe.
NOTE:
Use new O-rings.
39. Install the cylinder head.
40. Install the oil level gauge guide and tighten the attaching bolt (left side).
41. Install the rocker cover and rocker cover gasket.
NOTE:
Use a new gasket.
42. Install the crank sprocket.
43. Install the cam sprocket.
44. Install the timing belt.
45. Install the timing belt cover.
46. Install the crank pulley.
47. Install the generator and A/C compressor brackets on cylinder head.
48. Install the V-belts.
49. Install the intake manifold.