HOUSING ASSEMBLY (I)

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1.  Assemble in the order indicated in the table.

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1
Front housing
2
Front stationary gear
3
Thrust plate
(See Thrust Plate Assembly Note.)
4
Needle bearing
5
Plate
6
Front rotor
A: Side seal
B: Side seal spring
C: Corner seal
D: Corner seal plug
E: Corner seal spring
F: Side piece
G: Apex seal
H: Apex seal spring (short)
I: Apex seal spring (long)
(See Rotor Assembly Note.)
7
Steel ball
8
Spring
9
Oil jet plug
(See Oil Jet Plug Assembly Note.)
10
Eccentric shaft
11
Front rotor housing
(See Rotor Housing Assembly Note.)
12
Tubular dowel (front rotor housing side)
13
Intermediate housing
(See Intermediate Housing Assembly Note.)
14
Rear rotor
(See Rotor Assembly Note.)
15
Rear rotor housing
(See Rotor Housing Assembly Note.)
16
Tubular dowel (rear rotor housing side)
17
Pressure regulator (Type A)
18
Rear stationary gear
19
Rear oil seal
(See Rear Oil Seal Assembly Note.)
20
Rear housing
(See Rear Housing Assembly Note.)
21
Tension bolt
(See Tension Bolt Assembly Note.)
22
Flywheel (MT), counterweight (AT)
(See Flywheel (MT), Counterweight (AT) Assembly Note.)


Thrust Plate Assembly Note

1.  Place the chamfer side facing the stationary gear.

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Rotor Assembly Note

Caution
•  Assemble only the side seal and corner seal on the engine front side while the rotor is not assembled.

1.  Assemble the side seal spring in the direction shown in the figure.

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2.  Assemble the side seal spring in the direction shown in the figure.

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3.  Apply petroleum jelly between the side seal and side seal groove.

4.  Assemble the corner seal plug to the corner seal.

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Note
•  When replacing a corner seal with new one, assemble the corner seal with the painting surface facing upward.
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5.  Assemble the corner seal and corner seal spring with the notch aligned with the apex seal groove.

6.  Apply petroleum jelly between the corner seal and corner seal groove.

7.  Place the rotor in the housing.

8.  Insert the SST into the apex seal groove of the rotor and verify that the apex seal groove of the corner seal is aligned with the apex seal groove of the rotor.

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9.  Assemble the side seal and corner seal for the engine rear side in the same way as the engine front side.


Oil Jet Plug Assembly Note

Note
•  Be careful not to spill thread locking compound on the spring and ball.

1.  Apply thread locking compound to the threads of the oil jet plug.

2.  Install the oil jet plug.

Tightening torque
3.9—11.7 N·m
{40—119 kgf·cm, 35—103 in·lbf}


Rotor Housing Assembly Note

Caution
•  Assemble the seal rubber without any torsion.
•  Do not get oil or grease on the seal rubber.

1.  Apply petroleum jelly to a new seal rubber.

2.  Assemble the outer seal rubber to the housing with the white paint in the direction shown in the figure.

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3.  Assemble the inner seal rubber to the housing with the seal rubber joint placed between A—B.

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4.  Apply the silicone sealant to the position indicated in the figure.

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Bead thickness
2.5—6.5 mm {0.099—0.255 in}

5.  Apply thread locking compound to the attaching surface of the apex seal and the side piece and affix them.

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Caution
•  After adhesion, make sure that there is no gap between the apex seal and side piece.
•  If adhesive protrudes, remove with a razor.
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Note
•  When using a new apex seal, the procedure above is not needed.

6.  Assemble the apex seal and apex seal spring (short) together with the side piece to the engine rear side.

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7.  Assemble the apex seal spring (long) while pressing the apex seal spring (short).

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Caution
•  Assemble the apex seal spring until it catches the spring stopper of the side piece.


Intermediate Housing Assembly Note

Caution
•  Do not allow the side piece to be caught between the rotor housing and intermediate housing.
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1.  Assemble the intermediate housing with the support of an assistant pushing the eccentric shaft up approx. 3 cm {1.18 in}.

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Rear Oil Seal Assembly Note

1.  Assemble the oil seal using the SST.

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Caution
•  Insert the rear oil seal until it is reaches to the seating face.

Rear Housing Assembly Note

1.  Assemble the rear housing with the rear stationary gear and the internal gear of the rotor engaged.

Caution
•  Do not allow the side piece to be caught between the rotor housing and rear housing.
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Tension Bolt Assembly Note

1.  Apply engine oil to the tension bolt threads and assemble to the housing with a new seal washer.

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Caution
•  Assemble a tension bolt which has a seal washer with the rubber projection facing the housing side.

2.  Tighten the tension bolts in the order indicated in the figure in 2—3 passes.

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Tightening torque
31.4—39.2 N·m
{3.21—3.99 kgf·m, 23.2—28.9 ft·lbf}


Flywheel (MT), Counterweight (AT) Assembly Note

1.  Lock the flywheel (MT) or counterweight (AT) against rotation using the SSTs.

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2.  Tighten the locknut using the SST.

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Tightening torque
392—490 N·m
{40.0—49.9 kgf·m, 290—361 ft·lbf}