Engine Unit: Disassembly and Assembly: Assembly

Fig 1: Identifying Drain Plugs And Bolts

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• Apply sealant to the thread of water drain plugs (A) and (B).

  Use Genuine RTV Silicone Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

• Apply sealant to the thread of plug (C).

  Use Genuine High Strength Thread Locking Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

• Apply sealant to the threads of plug (D).

  Use Anaerobic Liquid Gasket or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

  NOTE: For Canada, (D) is not plug but block heater. Refer to [ENGINE UNIT: DISASSEMBLY AND ASSEMBLY ].
• Replace washers with new one.
• Tighten each plug as specified below.

Block Plug and Block Heater Installation 

• Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten bolts.
  Fig 2: Inserting Oil Jet Dowel Pin Into Cylinder Block Dowel Pin Hole

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1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
2. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block.
   Fig 3: Identifying Thrust Bearing

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   • Install thrust bearings with the oil groove facing crankshaft arm (outside).
   • Install thrust bearing with a projection on one end on cylinder block, Align projection with mating notch.
3. Install main bearings paying attention to the direction.
   Fig 4: Identifying Main Bearings Oil Hole And Oil Groves

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   • Main bearing with oil hole and groove goes on cylinder block. The one without them goes on lower cylinder block.
   • Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
   • When installing, align main bearing stopper protrusion to cutout of cylinder block and lower cylinder block.
   • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

• While turning crankshaft by hand, check that it turns smoothly.

1. Apply a continuous bead of liquid gasket using Tool to lower cylinder block as shown.
   Fig 5: Applying Continuous Bead Of Liquid Gasket Using Tool To Lower Cylinder Block

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   Tool number: WS39930000 (-) 

   Use Genuine RTV Silicone Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

   CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly.
2. Tighten lower cylinder block as follows:
   1. Apply new engine oil to threads and seat surfaces of the bolts.
   2. Tighten M8 bolts in numerical order as shown from No. 17 to 24.
      Fig 6: Lower Cylinder Block Bolts Tighten Sequence

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      Bolts 17 - 24: 22.1 N.m (2.3 kg-m, 16 ft-lb) 

      CAUTION: Wipe off completely any protruding liquid gasket on rear oil seal installation surface.
      NOTE: There are more processes to complete the tightening bolts. However stop procedure here to install rear oil seal.
3. Install rear oil seal. Refer to [REAR OIL SEAL: REMOVAL AND INSTALLATION ].
4. Restart tightening of lower cylinder block bolts as follows:
   1. Tighten M10 bolts in numerical order as shown from No. 1 to 16.
      Fig 7: Lower Cylinder Block Bolts Tighten Sequence

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      NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).

      Bolts 1 - 16: 35.3 N.m (3.6 kg-m, 26 ft-lb) 

   2. Turn M10 bolts 90° clockwise in numerical order from No. 1 to 16 using Tool.
      Fig 8: Turning Crankshaft Bolts

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      Tool number: KV10112100 (BT-8653-A) 

      CAUTION: Use angle wrench Tool to check tightening angle. Do not make judgement by visual inspection.
      • After installing the bolts, make sure that crankshaft can be rotated smoothly by hand.
      • Wipe off completely any protruding liquid gasket on front side of the engine.
      • Check the crankshaft end play. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].

1. Install new snap ring to the groove of piston rear side using suitable tool.
   • Insert it fully into groove to install.
2. Install piston to connecting rod.
   • Using industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approx. 60° to 70 °C (140° to 158 °F)]. From the front to the rear, insert piston pin into piston and connecting rod.
   • Assemble so that the front mark on the piston head and the cylinder number on connecting rod are positioned as shown.
     Fig 9: Identifying Piston Grade Number, Cylinder Number And Pin Grade Number

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3. Install new snap ring to the groove of the piston front side.
   • Insert it fully into groove to install.
   • After installing, make sure that connecting rod moves smoothly.

Fig 10: Installing Piston Rings Using Piston Ring Expander Or Suitable Tool

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• If there is stamped mark on ring, mount it with marked side up.
  Fig 11: Identifying Stamped Mark On Ring

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  NOTE: If there is no stamp on ring, no specific orientation is required for installation.
  Stamped mark:
  Top ring: -
  Second ring: R
• Position each ring with the gap as shown referring to the piston front mark.
  Fig 12: Positioning Ring With Gap

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• Check the piston ring side clearance. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].

• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protrusion with cutout of connecting rods and connecting rod bearing caps to install.
  Fig 13: Identifying Connecting Rods And Connecting Rod Bearing Caps

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• Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.

Fig 14: Installing Piston With Front Mark On Piston Head

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Tool number: EM03470000 (J-8037) 

• Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
  Fig 15: Matching Stamped Cylinder Number Marks On Connecting Rod

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• Be sure that front mark on connecting rod bearing cap is facing front of engine.

1. Apply engine oil to the threads and seats of connecting rod bolts.
2. Tighten connecting rod bolts.

   Connecting rod bolt: 19.6 N.m (2.0 kg-m, 14 ft-lb) 

3. Then tighten all connecting rod bolts 90° clockwise.
   Fig 16: Tightening Connecting Rod Bolts

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   CAUTION: Always use Tool. Avoid tightening based on visual check alone.

   Tool number: KV10112100 (BT-8653-A) 

   • After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
   • Check the connecting rod side clearance. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].

Fig 17: Installing Pilot Converter

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• With drift of the following outer diameter, press-fit as far as it will go.

  Pilot converter: Approx. 33 mm (1.30 in) 

• Press-fit pilot converter with its chamfer facing crankshaft as shown.
  Fig 18: Pressing Pilot Converter With Chamfer Facing Crankshaft

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Fig 19: Installing Knock Sensors

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• Install knock sensor so that connector faces rear of engine.
• After installing knock sensor, connect harness connector, and lay it out to rear of engine.
  CAUTION:

  • Do not tighten bolts while holding connector.
  • If any impact by dropping is applied to knock sensor, replace it with new one.
  NOTE:

  • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
  • Make sure that knock sensor does not interfere with other parts.

Drive plate (A/T models) 

• Install drive plate and reinforcement plate as shown.
  Fig 20: Installing Drive Plate And Reinforcement Plate

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• Holding ring gear using Tool.

  Tool number: - (J-48761) 

• Tighten bolts crosswise over several times.