Part 1

ENGINE UNIT

COMPONENTS:

REASSEMBLY (STEPS 1-20)

1. INSTALL STUD BOLT

2. INSTALL STRAIGHT PIN

3. INSTALL RING PIN

4. INSTALL PISTON PIN HOLE SNAP RING
a. Using a screwdriver, install a new snap ring at one end of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

5. INSTALL W/PIN PISTON SUB-ASSEMBLY

a. Gradually heat the piston to about 80°C (176°F).

b. Coat the piston pin with engine oil.
c. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb until the pin contacts the snap ring.

6. INSTALL PISTON PIN HOLE SNAP RING
a. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

7. INSTALL PISTON RING SET

a. Install the oil ring expander and the 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings.

HINT: The compression ring No. 2 is installed with code mark 2A faced upward as shown in the illustration.

c. Position the piston rings so that the ring ends are arranged as shown in the illustration.

NOTICE: Do not align the ring ends.

8. INSTALL CONNECTING ROD BEARING
a. Align the key of the bearing with the keyway of the connecting rod or connecting cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.

9. INSTALL CRANKSHAFT BEARING

a. Clean each main journal and the bearing.

HINT: Main bearings come in widths of 22.4 mm (0.882 inch) and 19.0 mm (0.748 inch). Install the 22.4 mm (0.882 inch) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 inch) bearings in the No. 2 and No. 3 positions.

b. Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings.

NOTICE: Do not apply engine oil to the bearing and its contact surface.

c. Align the key of the bearing with the keyway of the main bearing cap, and push in the 4 lower bearings.

NOTICE: Do not apply engine oil to the bearing and its contact surface.

HINT: A number is marked on each main bearing cap to indicate the installation position.

10. INSTALL CRANKSHAFT THRUST WASHER SET

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

b. Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.

11. INSTALL CRANKSHAFT
a. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.

b. Examine the front marks and numbers and install the bearing caps on the cylinder block.
c. Apply a light coat of engine oil to the threads of the bearing cap bolts.
d. Temporarily install the 8 main bearing cap bolts to the inside positions.

e. Install the main bearing cap by hand using the inner bolt as a guides. Stop the main bearing cap is about 6 mm (0.23 inch) away from contacting with the block.

f. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
g. Apply a light coat of engine oil on the threads of the main bearing cap bolts.

h. Using several steps, install and tighten the 16 main bearing cap bolts uniformly in the sequence shown in the illustration (procedure A).
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)

i. Mark the front side of the bearing cap bolts with paint.
j. Retighten the bearing cap bolts by 90° in the same sequence as procedure A.
k. Check that each painted mark is now at 90° angle to the front.
l. Check that the crankshaft turns smoothly.

m. Using several steps, install and tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

HINT: Use the short bolt for the marked position (arrow).

12. INSTALL PISTON SUBASSEMBLY W/CONNECTING ROD

a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
b. Check the position of the piston ring ends.
c. 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.

NOTICE: Match the numbered connecting rod cap with the connecting rod.

d. Check that the protrusion of the connecting rod cap is facing the correct direction.
e. Apply a light coat of engine oil on the threads of the connecting rod cap bolts.

f. Tighten the bolts in several steps to the specified torque.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

g. Mark the front side of each connecting cap bolt with paint.
h. Retighten the cap bolts by 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.

13. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 1 PLUG
a. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

14. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 2 PLUG
a. Using a socket hexagon wrench 10 mm, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

15. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 3 PLUG
a. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)

16. INSTALL WATER SEAL PLATE
a. Remove any old seal packing from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the seal plate within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the seal plate with the 2 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)

17. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)

NOTICE:
^ Install the drain cock within 3 minutes after applying adhesive.
^ Do not expose the seal to coolant within 1 hour after installing.
^ Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock to the specified torque.
^ Do not loosen the drain cock after setting it correctly.

18. INSTALL SPARK PLUG TUBE GASKET
a. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
b. Return the ventilation plate tab to its original position.
c. Apply a light coat of MP grease to the gasket lip.

19. INSTALL ENGINE REAR OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.

b. Apply MP grease to the oil seal lip.

20. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing material from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from contact surface.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)