Assembly
Cylinder Block Internal Components:
1. Install the oil baffle plate.
^ Apply locking agent to the baffle plate screws; then install the baffle plate to the cylinder block.
Tightening torque: 7.9-10.7 Nm (70-95 in lbs.)
2. Install the upper main bearings and the upper thrust bearing.
^ Apply clean engine oil to the bearings.
3. Install the crankshaft.
^ Apply clean engine oil to the crankshaft journals.
4. Install the lower main bearings and the lower thrust bearing.
^ Apply clean engine oil to the bearings.
5. Install the main bearing caps.
a. Install the main bearing caps according to the can number and mark.
b. Tighten the main bearing cap bolts.
(1) Measure each bolt length. Replace if necessary.
Length: 84.7-85.3 mm (3.34-3.35 in)
Maximum: 85.5 mm (3.37 in)
Main Torque Sequence:
(2) Tighten the bolts in three steps in the order shown.
Tightening torque: 17.2-22.0 Nm (12.7-16.2 ft lbs.)
(3) Put a paint mark on each bolt head.
(4) Using this mark as a reference, tighten the bolts by turning each 85°-95° in the sequence.
(5) Further tighten each bolt by turning another 40°-50°.
(6) Verify that the crankshaft rotates smoothly by hand.
c. Inspect the crankshaft end play.
6. Install the pistons and the upper connecting rod bearings.
a. There are three standard cylinder bores and matching piston sizes. The pistons and bores must agree if installing new pistons in a standard size bore.
b. The pistons and cylinder block are marked as shown in the figures (A, No mark or B). Refer to the charts for piston and bore sizes.
Cylinder block (Bore size)
Mark - Size
A - 90.015-90.022 mm (3.5439-3.5441 in)
No mark - 90.007-90.015 mm (3.5436-3.5438 in)
C - 90.000-90.007 mm (3.5433-3.5435 in)
Piston (Measured at 90° to pin bore axis and 22.0 mm (0.866 in) below oil ring groove)
Mark - Size
A - 89.971-89.990 mm (3.5422-3.5429 in)
No mark - 89.965-89.983 mm (3.5420-3.5426 in)
C - 89.958-89.977 mm (3.5417-3.5423 in)
c. Apply clean engine oil to the cylinder walls, piston, piston rings and connecting rod bearings.
d. Check the piston rings for the end gap alignment.
e. Insert each piston into the cylinder block with L mark (left bank) or R mark (right bank) faces the front of the engine. Use a piston installer tool to install.
7. Install the lower connecting rod bearings.
^ Apply clean engine oil to the bearings.
8. Install the connecting rod caps.
a. Apply clean engine oil to the crankpin journal and connecting rod bearing.
b. Install the connecting rod cap with the alignment marks aligned.
c. Tighten the connecting rod cap nuts.
(1) Tighten the nuts to 27.0-31.8 Nm (19.9-23.5 ft. lbs.)
(2) Put a paint mark on each nut head.
(3) Using the paint mark as a reference, tighten the nuts 82.5°-97.5°.
(4) Verify that the crankshaft rotates smoothly by hand.
Cylinder Block External Components:
Cylinder Block External Components (Part 2 Of 2):
9. Install the front oil seal.
a. Apply clean engine oil to the lip of the new oil seal.
b. Push the oil seal into the oil pump body by hand.
c. Press the oil seal into the oil pump body by using the SST.
10. Install the oil pump.
a. Install the oil pump with a new gasket.
Tightening torque: 19-25 Nm (14-18 ft lbs.)
b. Cut away the portion of the gasket that projects from the body toward the oil pan side.
11. Install the timing belt.
12. Install the water pump.
13. Install the thermostat.
14. Install the rear oil seal.
a. Apply clean engine oil to the lip of new oil seal.
b. Push the oil seal into the rear cover by hand.
c. Press the oil seal into the rear cover by using the SST.
15. Install the rear cover.
a. Install the rear cover and a new gasket.
Tightening torque: 7.9-10.7 Nm (70-95 in lbs.)
b. Cut away the portion of the gasket that projects from the body toward the oil pan side.
16. Install the oil strainer.
17. Install the oil pan.
a. Remove the old sealant from the oil pan bolts and bolt holes in the cylinder block.
CAUTION: If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage.
b. Apply silicone sealant and install oil pan.
c. Apply silicone sealant to the oil pan along the inside of the bolt holes, overlap the ends, and install the oil pan within five minutes.
d. Tighten the oil pan bolts.
Tightening torque: 6.9-9.8 Nm (61-86 in lbs.)
18. Install the end plate.
19. Install and tighten, in sequence, the backing plate, adapter, drive plate, and plate by using the SST.
Tightening torque: 103-109 Nm (76.0-81.0 ft. lbs.)
20. Install the cylinder head.
a. Measure the amount of oil control plug projection from the deck of the cylinder block.
Projection: 5.3-5.7 mm (0.209-0.224 in)
b. Apply clean engine oil to new O-rings and install them to the oil control plugs.
c. Thoroughly remove all dirt, oil, and other material from the top of the cylinder block.
d. Turn the crankshaft clockwise and apply engine oil to the cylinder walls.
e. Place a new cylinder head gasket on the left bank with the L mark facing upward.
f. Place a new cylinder head gasket on the right bank with the R mark facing upward.
g. Install the cylinder head to the cylinder block.
h. Tighten the cylinder head bolts.
Head Bolt Length:
(1) Before installation, measure each bolt length. Replace if necessary.
Length
IN: 107.7-108.3 mm (4.25-4.26 in)
EX: 137.7-138.3 mm (5.43-5.44 in)
Maximum
IN: 109 mm (4.29 in)
EX: 139 mm (5.47 in)
Head Torque Sequence:
(2) Tighten the bolts in the order shown.
Tightening torque: 17.2-22.0 Nm (12.7-16.2 ft lbs.)
(3) Put a paint mark on each bolt head.
(4) Using the mark as a reference, tighten the bolts 85°-95° in the sequence shown.
(5) Retighten each bolt another 85°-95° in the sequence shown.
21. Install the seal plate.
22. Install the cylinder head cover.
a. Remove all old silicone sealant from the cylinder head and cylinder head cover.
b. Coat a new gasket with silicone sealant, and install it onto the cylinder head cover.
c. Install the cylinder head cover along with new seal washers.
Tightening torque: 3.5-4.4 Nm (31-39 in lbs.)
23. Install the intake manifold.
Timing Components:
24. Install the timing belt auto tensioner.
a. Set a plain washer at the bottom of the tensioner body to prevent damage to the body plug.
b. Press in the tensioner rod slowly by using a press.
CAUTION: Pressing the tensioner rod with more than 9,807 Nm (2,200 lbs.) can damage the tensioner spring.
c. Insert a pin to hold the tensioner rod in the body as shown.
d. Install the auto tensioner to the cylinder block.
Tightening torque: 19-25 Nm (14-18 ft. lbs.)
25. Install the timing belt.
a. Install the crankshaft pulley lock bolt and hand tighten it.
b. Turn the camshaft pulleys clockwise and align the timing marks.
c. Position the timing belt in the original direction, and hang it on each pulley in the order shown.
CAUTION: The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it.
d. Install the upper idler pulley.
Tightening torque: 38-51 Nm (28-38 ft lbs.)
e. Turn the crankshaft clockwise twice and align the timing marks.
f. Check that the timing marks are correctly aligned. If not, repeat steps b-e.
g. Remove the pin from the auto tensioner.
h. Turn the crankshaft clockwise twice and align the timing marks.
i. Reconfirm that the timing marks are correctly aligned.
j. Check the timing belt deflection by applying moderate pressure 98 N (22 lbs.) midway between the timing belt pulley and the auto tensioner. If not correct, repeat the adjustment from step e.
Timing belt deflection: 5-7 mm (0.2-0.27 in)
k. Remove the crankshaft pulley lock bolt.
26. Install the timing belt cover.
^ Install the timing belt covers along with new gaskets.
^ Tighten the bolts in the order shown.
Tightening torque:
M6: 7.9-10.7 Nm (70-95 in lbs.)
M10: 38-51 Nm (28-38 ft. lbs.)
27. Install the crankshaft pulley.
a. Install the crankshaft pulley and hand tighten the pulley lock bolt.
CAUTION: The crankshaft position sensor rotor is on the rear of the crankshaft pulley, and can be damaged easily.
b. Mount SST# 49 S120 710 on the crankshaft pulley to hold the crankshaft.
c. Tighten the crankshaft pulley lock bolt.
Tightening torque: 157-166 Nm (116-122 ft lbs.)
Engine Auxiliary Components:
28. Install the oil filter.
29. Install the dipstick.
30. Install the exhaust manifold.
31. Install the exhaust manifold insulator.
32. Install the distributor.
a. Apply clean engine oil to the new O-ring, and position it on the distributor.
b. Apply clean engine oil to the drive gear, and match the matching marks as shown.
c. Install the distributor into the cylinder head with the marks facing straight up.
d. Hand tighten the distributor mounting bolt.
33. Install the water bypass hose.
34. Install the water inlet pipe.
35. Install the engine hanger.
36. Install the A/C idler pulley and compressor bracket.
37. Install the power steering idler pulley.
38. Install the LH engine mount.