Engine - Assembly

Engine - Assembly
Special Service tools





Wrench Strap-Universal
303-D055





Crankshaft Rear Seal Installer
303-178





Crankshaft Rear Seal Installer Adapter Bolts
303-384





Piston Ring Compressor
303-372





Cylinder Bore Protector
303-535

Assembly

1. CAUTION: Use only plastic scraper when removing old gasket material.

Clean all the mating faces and reusable parts thoroughly and check for damage.
^ If gasket material remains on the cylinder head after cleaning, use a plastic tipped scraper to remove remaining material.

2. NOTE: Never remove pipe plugs or alignment dowels unless they are to be serviced.

Reseal oil passage blanking plugs, as necessary.





3. NOTE: The main bearings are precision selective fit.

Install the upper crankshaft thrust washer.
^ Align assembly tab on thrust bearing to machining spot face on cylinder block.





4. Install the upper crankshaft main bearings.
^ Lubricate the bearings and thrust washer.





5. CAUTION: Avoid damage to any crankshaft journal bearing surfaces.

Install the crankshaft.





6. NOTE: Push the crankshaft rearward prior to installation of upper thrust bearings.

NOTE: Visually inspect the bearings to verify that the bearing oiling holes align with cylinder block oil feed holes.

Install the lower crankshaft bearings into the cylinder block.
1. Install the lower crankshaft thrust main bearing into lower cylinder block.
2. Install the lower crankshaft main bearings into lower cylinder block. Lubricate the bearings and thrust washer.





7. NOTE: Sealant application must stop 6 mm from the rear crankshaft bore on each side.

NOTE: Install lower cylinder block and tighten all bolts to specification within four minutes of applying sealer.

Apply a bead of sealant to the cylinder block housing.
^ Use Silicone gasket and sealant





8. CAUTION: Make sure all dowels are fully seated into lower cylinder block prior to tightening the bolts.

NOTE: Before installing the bolts lightly seat the crankshaft forward.

NOTE: Do not lubricate the lower cylinder block bolts.

NOTE: Loosely install the lower cylinder block bolts.

NOTE: Do not rotate crankshaft until all bolts are tightened to specification.

NOTE: Bolts must be tightened within 4 minutes of applying sealant.

Install the lower cylinder block on the cylinder block.
^ Push crankshaft rearward to seat the crankshaft thrust washer.





9. CAUTION: Bolts 1 through 16 are tighten-to-yield and must be replaced.

NOTE: Tighten the bolts in the indicated sequence in four stages.

Complete the tightening sequence.
^ Stage 1: Bolts 1-8, 25 Nm
^ Stage 2: Bolts 9-16, 40 Nm
^ Stage 3: Bolts 1-16, 90°
^ Stage 4: Bolts 17-22, 25 Nm
^ Verify the crankshaft rotates freely.

10. Remove excess sealant which may squeeze out at the front cover sealing surface.





11. NOTE: Alternate bolt tightening to correctly seat the crankshaft rear oil seal until it is flush with the cylinder block.

Using the special tools, install the crankshaft rear oil seal.

12. CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surfaces.

Install special tools to the connecting rods.
^ Position the crankshaft journal at the bottom of the stroke.





13. NOTE: Make sure the piston ring gaps are positioned at different locations opposite the thrust side of the piston before installation.

NOTE: Install pistons with arrow to front of engine.

Using the special tool compress the rings and install the piston and connecting rod.
^ Lubricate all piston components.





14. CAUTION: When assembling the connecting rods and connecting rod caps, it is imperative that bearing slots and tangs be located on the same side of the connecting rods.

CAUTION: Connecting rod bolts are torqued to yield and must be replaced.

NOTE: Remove the special tools from the connecting rods.

NOTE: Tighten the bolts in the indicated sequence in three stages.

Position the connecting rod cap on the appropriate connecting rod.
^ Stage 1: 23 Nm
^ Stage 2: 43 Nm
^ Stage 3: 105°

15. Rotate the crankshaft to check correct operation.





16. CAUTION: Install the oil pump flush to the cylinder block for correct sealing.

CAUTION: Rotate the inner rotor of the oil pump to align with the flats on the crankshaft before installation.

Install the oil pump.
^ Tighten to 10 Nm.





17. CAUTION: Oil pan baffle nuts are tightened to yield and must not be reused.

NOTE: Tighten the bolts in the indicated sequence in two stages.

Install the oil pan baffle.
^ Stage 1: 5 Nm
^ Stage 2: 45°





18. NOTE: Engine inverted for clarity.

Install the oil pump tube.
^ Install a new O-ring seal.
^ Tighten to 10 Nm.





19. NOTE: Engine inverted for clarity.

Tighten to 5 Nm + 45°.





20. Install the engine coolant housing.
^ Install new O-ring seals.
^ Tighten to 25 Nm.





21. Position the crankshaft.
^ Turn the crankshaft until the key is in the 11 O'clock position.
^ Remove the crankshaft pulley bolt and washer.





22. Install a new cylinder head gasket (LH shown - RH similar).
1. Make sure the cylinder head dowels are correctly located.
2. Install a new cylinder head gasket.