Reassembly
Reassembly
NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and the connecting rod.
(1) Install the snap ring in one side of the piston pin hole.
(2) Align the piston front mark and the connecting rod front mark.
(3) Insert the piston pin into the piston pin hole and the small end bore of connecting rod.
(4) Install the snap ring in the other side after inserting the piston pin.
NOTE:
Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the connecting rod before inserting the piston pin.
2. Install the piston rings.
(1) Install the oil ring spacer and 2 side rails 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.
3. Install the connecting rod bearings.
(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).
4. Install the main bearings (A) (No.1,2,4,5 journal) and the center bearings (B) (No.3 journal).
NOTE:
Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the lower crankcase and push in the 5 lower bearings.
5. Place the crankshaft(A) on the cylinder block.
6. Place the lower crankcase assembly on cylinder block.
(1) Using a gasket scraper, remove all the old gasket material from the gasket surfaces.
(2) Install the O-ring (A) to cylinder block.
(3) Before assembling the lower crankcase assembly, the liquid sealant LT 5900H or TB1217 should be applied on cylinder block bottom.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width :2.5mm(0.1in)
NOTE:
- Clean the sealing face before assembling two parts.
- Remove harmful foreign materials on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not protrude into the inside of cylinder block.
- To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
(4) Install the lower crankcase assembly.
7. Install the lower crankcase assembly bolts.
(1) Install and uniformly tighten the lower crankcase assembly bolts, in several passes, in the sequence shown.
Tightening torque
Main bearing cap bolts (1 - 20)
37.3 - 41.2 N.m
(3.8 - 4.2 kgf.m, 27.5 - 30.4 lb-ft) + 120°
Flange bolts (21 - 35)
21.6 - 25.5 N.m (2.2 - 2.6 kgf.m, 15.9 - 18.8 lb-ft)
NOTE:
- Always use new main bearing cap bolts.
- If any of the bearing cap bolts are broken or deformed, replace it.
Use the SST( 09221-4A000 ), install main bearing cap bolts.
(2) Check that the crankshaft turns smoothly.
8. Check crankshaft end play.
9. Install the piston and connecting rod assemblies.
NOTE:
- Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
- The piston front mark (A) and the connecting rod front mark (B) must face the timing chain side of the engine.
(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 :
22.6 - 26.5Nm (2.3 - 2.7kgf.m, 16.6 - 19.5lb-ft) + 98 - 102°
Use SST(09221-4A000), install connecting rod bearing cap bolts.
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.
10. Check the connecting rod end play.
11. Install the cylinder block rear cover (A) and a new gasket.
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
- Clean the sealing face before assembling two parts.
- Remove harmful foreign materials on the sealing face before applying sealant.
- Before assembling oil drain cover, the liquid sealant LT 5900H or TB1217 should be applied to the oil drain cover.
- The part must be assembled within 5 minutes after sealant was applied.
- Apply sealant to the inner threads of the bolt holes.
12. Install the crankshaft adapter plate (A).
13. Using the SST(09231-2J400, 09231-H1100) and a plastic hammer, tap in a new oil seal(A) until SST surface is flush with the cylinder block.
At this time, the depth of the oil seal(A) from the cylinder block surface is 1mm(0.039in).
NOTE:
- Before assembling oil seal, the hardened sealant or injurious material located on the boundary area between cylinder block and lower crankcase must be removed.
- Apply engine oil to a new oil seal lip.
- When pressing oil seal, confirm to direction and take care not to damage oil seal.
14. Install the cylinder block bank cover (A) and a new gasket (B).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
The "F"mark of the gasket must be face the front of the engine.
15. Install the separator (A).
16. Install the drive plate (B) and the adapter plate (A).
Tightening torque :
98.1 - 107.9N.m(10.0 - 11.0kgf.m,72.3 - 79.6lb-ft)
17. Install the oil pump.
18. Install the water temperature control assembly.
19. Install the timing chain.
20. Install the cylinder head.
21. Install the intake manifold and exhaust manifold.
22. Remove the engine from engine stand.
23. Install the engine assembly to the vehicle.