Repair Procedures: Reassembly

1. Use a hydraulic press for installation
2. The piston front mark and the connecting rod front mark must face the timing chain side of the engine.

Fig 1: Identifying Front Marks Of Piston & Connecting Rod

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1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown in Fig 2.

Fig 2: Installing Piston Rings

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1. Align the bearing (A) claw with the groove of the connecting rod or connecting rod cap (B).
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).

Fig 3: Identifying Bearing & Connecting Rod Cap

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1. Align the bearing claw with the claw groove of the cylinder block, push in the five upper bearings (A).
   Fig 4: Pushing In Upper Bearings

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2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

Install the thrust bearing (A) on the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 5: Identifying Thrust Bearing

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1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown in Fig 6.

   Tightening torque: 

   1st - 17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)

   2nd - 88° ~ 92°

   Fig 6: Main Bearing Cap Bolts Tightening Sequence

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   CAUTION: Do not reuse the main bearing cap bolts.
3. Check that the crankshaft turns smoothly.

1. Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
2. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
3. Install the rod caps with bearings, and tighten the bolts. (Do not reuse the bolts).

   Tightening torque: 

   1st - 17.7 ~ 21.8N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)

   2nd - 88° ~ 92°

Tightening torque: 

18.6 ~ 24.2N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

Fig 8: Identifying Ladder Frame

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1. Apply engine oil to a new oil seal lip.
2. Using the SST (09231-H1100, 09231-2B200) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

Fig 9: Installing Rear Oil Seal Using SST & Hammer

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Install a new gasket and oil screen with 2 bolts.

Tightening torque: 

19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

Fig 10: Installing Oil Screen

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1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
   NOTE: Check that the mating surfaces are clean and dry before applying liquid gasket.
2. Apply liquid gasket with the width of ø3mm, starting 1mm-away position from the inner rounding of the oil pan rail.

   Liquid gasket  : TB 1217H or LOCTITE 5900H

   Fig 11: Installing Oil Pan

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   NOTE:

   • To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
   • Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
   • After assembly, wait at least 30 minutes before filling the engine with oil.
3. Install the oil pan (A) with the bolts.

   Uniformly tighten the bolts in several passes.

   Tightening torque: 

   9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

   Fig 12: Identifying Oil Pan & Bolts

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1. Apply adhesive to 2 or 3 threads.
2. Install the oil pressure switch (A).

Tightening torque: 

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

Fig 13: Identifying Oil Pressure Switch

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Tightening torque: 

16.7 ~ 26.5N.m (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lb-ft)

Fig 14: Identifying Knock Sensor & Oil Filter

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1. Install a new O-ring on the oil level gauge tube.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge tube with the bolt.

   Tightening torque: 

   9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Tightening torque: 

71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)

Tightening torque: 

71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)