Engine Block Overhaul: Installation

NOTE:

Where icon is shown for further information continue to the information below.
Be careful not to damage the journals and the CKP pulse plate.

Fig 1: CKP Pulse Plate Replacement Components With Torque Specifications

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	Detailed information, notes, and precautions
	Torque: N.m (kgf.m, lbf.ft)
*1	These parts have inspection items.

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	Detailed information, notes, and precautions
*1	These parts have inspection items.

Fig 2: Engine Block Replacement Components With Torque Specifications

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	Detailed information, notes, and precautions
	Torque: N.m (kgf.m, lbf.ft)
	Replace

Main Bearing Clearance - Inspect
CKP Pulse Plate - Install
NOTE: Apply new engine oil to the bolt threads and flanges
Crankshaft - Install
NOTE: Apply a coat of new engine oil to the main bearings.

Thrust Washer - Install

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1. Apply new engine oil to the side with the thrust washer groove. Install the thrust washers (A) in the No. 3 journal.

Main Bearing Cap and Bearing Half - Install

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1. Install the main bearings (A) and the main bearing caps (B) with the arrow (C) facing the timing belt side of the engine block.

2. Apply new engine oil to the bolt threads and flanges, then loosely install the bearing cap bolts (D) and the bearing cap side bolts (E).

3. Set the crankshaft to bottom dead center (BDC) for the cylinder.

Fig 3: Main Bearing Cap Bolts Tightening Sequence

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4. Tighten the main bearing cap bolts (A), then tighten the main bearing cap side bolts (B) to the specified torque in the sequence as shown. Repeat the torque sequence again to ensure the bolts are properly torqued.

Specified Torque

5. Remove all of the old liquid gasket from the engine block end cover mating surfaces, the bolts, and the bolt holes.

6. Clean and dry the engine block end cover mating surfaces and the crankshaft oil seal housing.

A:	40 N.m (4.1 kgf.m, 30 lbf.ft) + 47°
B:	49 N.m (5.0 kgf.m, 36 lbf.ft)

Piston Pin - Install

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1. Install a piston pin snap ring (A) only on one side.

2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil.

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3. Heat the piston to about 158°F (70°C).

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4. Make sure the mark (A).

MARK:

R9P or 5J6

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R9P

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5J6

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5. Assemble the piston (A) and the connecting rod (B).
NOTE:

Align the arrow (C) with the groove (D) direction on the connecting rod as shown.
Pay attention to the direction for installing the connecting rod according to the marks.

6. Install the piston pin (E).

7. Install the remaining snap ring (F).

8. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.

Piston Ring - Install

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1. Install the rings as shown. The top ring (A) has a 1A mark or 1R mark, and the second ring (B) has a SPR mark. The manufacturing marks (C) must be facing upward.

2. After installing a new set of rings, measure the ring-to-groove clearance.

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3. Rotate the rings in their grooves to make sure they do not bind.

4. Position the ring end gaps as shown.

Piston/Connecting Rod Assembly - Install

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1. Apply a coat of new engine oil to the connecting rod bearings.

2. Install the ring compressor, and check that the bearing is securely in place.

3. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly.

4. Position the piston/connecting rod assembly with the arrow (A) facing the timing belt side of the engine block.

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5. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.

6. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.

Connecting Rod Bearing Clearance - Inspect

Connecting Rod Cap and Bearing Half - Install

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1. Measure the diameter of each connecting rod bolt at point A and point B.

2. Calculate the difference in diameter between point A and point B.

Difference in Diameter

3. If the difference in diameter is out of tolerance, replace the connecting rod bolt.

Specification:

0-0.1 mm (0-0.004 in)

Point A-Point B =

Difference in Diameter

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4. Install the connecting rod bearing (A), then line up the mark (B) on the connecting rod (C) and the rod cap (D).

5. Apply new engine oil to the bolt threads and flanges. Torque the bolts (E) to 20 N.m (2.0 kgf.m, 15 lbf.ft).

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6. Tighten the connecting rod bolt an additional 90°
NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and inspect the connecting rod bolt. Do not loosen it back to the specified angle.

Drain Bolt - Install (If removed)
Sealing Bolt - Install (If removed)
Engine Block End Cover - Install
NOTE:
- Apply a light coat of new engine oil to the lip of the crankshaft oil seal.
- Apply liquid gasket to the engine block end cover mating surface of the engine block end cover and to the inside edge of the threaded bolt holes.
- Replace the transmission end crankshaft oil seal as needed .
Baffle Plate - Install
Oil Pump - Install
Oil Strainer - Install
Oil Pan - Install
Drive Plate - Install
Transmission - Install