GSIC - Global Service Information Center

# ENGINE UNIT > REASSEMBLY

## for Preparation Click here

1. INSTALL TIGHT PLUG

1. Apply adhesive to the end of a new tight plug.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent

   NOTICE:
     Do not start the engine for 1 hour after the installation.

1. Position A:
   Using a 14 mm steel bar and hammer, tap in the tight plug as shown in the illustration.

1. Other Positions:
   Using SST and a hammer, tap in a new tight plug as shown in the illustration.
   Position B

   SST
     09950-60010 (09951-00180)
     09950-70010 (09951-07100)
   Position C
   SST
     09950-60010 (09951-00190)
     09950-70010 (09951-07100)
   Position D
   SST
     09950-60010 (09951-00200)
     09950-70010 (09951-07100)
   Position E
   SST
     09950-60010 (09951-00350)
     09950-70010 (09951-07100)
   Position F
   SST
     09950-60010 (09951-00400, 09951-00450)
     09950-70010 (09951-07100)
   Position G
   SST
     09950-60010 (09951-00450)
     09950-70010 (09951-07100)

2. INSTALL STUD BOLT

3. INSTALL STRAIGHT PIN

4. INSTALL RING PIN

5. INSTALL NO. 1 STRAIGHT SCREW PLUG

1. Install a new gasket and the screw plug.

   Torque:
     25 N*m{ 255 kgf*cm , 18 in.*lbf }

6. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

1. Align the pin of the oil nozzle with the pin hole of the cylinder block.

1. Install the oil nozzle with the check valve. Install the 4 oil nozzles and check valves.

   Torque:
     26 N*m{ 265 kgf*cm , 19 in.*lbf }

7. INSTALL PISTON PIN

1. Assemble the piston and connecting rod.

   1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

   2. Gradually heat the piston to about 60°C (140°F).

   3. Coat the piston pin with engine oil.

   4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

   5. Check fit between the piston and piston pin. Try to move the piston back and forth on the piston pin.

   6. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

1. Install the piston rings.

   1. Install the coil and oil ring by hand.

      HINT:
        Face the end gap of the oil ring in the opposite direction of the coil joint.

   2. Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

      Code mark:

        Number | Mark
        No. 1 | N1
        No. 2 | N2

   3. Position the piston rings so that the ring ends are as shown.

      NOTICE:
        Do not align the ring ends.

8. INSTALL CONNECTING ROD BEARING

1. Align the bearing claw with the groove of the connecting rod or connecting cap.

1. Install the bearings in the connecting rod and connecting rod cap.

9. INSTALL CRANKSHAFT BEARING

HINT:

  Upper bearings have an oil groove and oil hole. Lower bearings do not.

1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

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

10. INSTALL CRANKSHAFT

1. Place the crankshaft on the cylinder block.

1. Install the 2 upper thrust washers to the No. 5 journal position of the cylinder block.

   1. Push the crankshaft toward the front (rear) side.

   2. Install the 2 thrust washers with the oil grooves facing outward.

1. Install the 2 thrust washers on the No. 5 bearing cap with the grooves facing outward.

1. Install the 5 crankshaft bearing caps in their proper locations.

1. Install the crankshaft bearing cap bolts.

   HINT:
   1. The main bearing cap bolts are tightened in 2 progressive steps.
   2. If a main bearing cap bolt is broken or deformed, replace it.

   1. Apply a light coat of the engine oil on the threads and under the bolt heads of the main bearing caps.

   2. Install and uniformly tighten the 10 bolts of the main bearing caps in several passes in the sequence shown in the illustration.

      Torque:
        50 N*m{ 510 kgf*cm , 37 ft.*lbf }
      If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.

   3. Mark the front of the main bearing cap bolt with paint.

   4. Retighten the main bearing cap bolts 90° in the numerical order shown on previous page.

   5. Check that the painted mark is now at a 90° angle to the front.

1. Check that the crankshaft turns smoothly.

1. Check the crankshaft thrust clearance.

11. INSTALL PISTON AND CONNECTING ROD

1. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

1. Place the connecting rod cap on the connecting rod.

   1. Match the numbered connecting rod cap with the connecting rod.

   2. Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

   3. Check that the front mark of the connecting rod cap is facing forward.

1. Install the connecting rod cap bolts.

   HINT:
   1. The connecting rod cap bolts are tightened in 2 progressive steps.
   2. If any connecting rod bolt is broken or deformed, replace it.

   1. Apply a light of engine oil on the threads and under the heads of the connecting rod cap bolts.

   2. Install and alternately tighten the bolts of the connecting rod cap in several passes.

      Torque:
        35 N*m{ 357 kgf*cm , 26 ft.*lbf }
      If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolts.

   3. Mark the front of the connecting rod cap bolts with paint.

   4. Retighten the connecting rod cap bolts 90° as shown.

   5. Check that the painted mark is now at a 90° angle to the front.

1. Check that the crankshaft turns smoothly.

1. Check the connecting rod thrust clearance (Click here).

12. INSTALL CYLINDER BLOCK OIL ORIFICE

13. INSTALL SUPPLY PUMP GEAR BEARING

1. Using SST and a press, press in a new bearing.

   SST
     09223-00010
     09223-15020
     09502-12010
     09950-70010 (09951-07100)

14. INSTALL REAR ENGINE OIL SEAL RETAINER

1. Remove oil seal packing (FIPG) from oil pan and cylinder block.

1. Apply seal packing to the specific places described in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     3 to 5 mm (0.12 to 0.20 in.)

   NOTICE:
     After applying FIPG, install the engine rear oil seal retainer within 3 minutes and tighten its bolts within 15 minutes.

1. Install the retainer with the 7 bolts. Alternately tighten the 7 bolts in several passes.

   Torque:
     13 N*m{ 133 kgf*cm , 9.6 in.*lbf } for bolt A
     16 N*m{ 163 kgf*cm , 12 in.*lbf } for bolt B

15. INSTALL TIMING GEAR CASE ASSEMBLY

1. Remove any old packing (FIPG) material.

1. Apply seal packing to the timing gear case as shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     5 mm (0.20 in.)

   NOTICE:
     Install the timing gear case assembly within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

1. Install a new gasket to the groove of the timing gear case.

1. Install 2 new O-rings to the cylinder block groove of the timing gear case.

1. Align the mark on the oil pump drive gear with the mark on the timing gear case.

1. Install the timing gear case with the union bolt and 8 bolts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf } for union bolt (A)
     16 N*m{ 163 kgf*cm , 12 ft.*lbf } for bolt

1. Remove the screw plug.

1. Pour in approximately 20 cc (0.12 cu in.) of engine oil into the oil pump.

1. Reinstall a new gasket and the screw plug.

   Torque:
     44 N*m{ 449 kgf*cm , 32 ft.*lbf }

16. INSTALL OIL STRAINER SUB-ASSEMBLY

1. Install a new gasket and the oil strainer with the 2 bolts and nut.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

17. INSTALL OIL PAN SUB-ASSEMBLY

1. Remove any old packing (FIPG) material.

1. Apply seal packing to the oil pan as shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     5 mm (0.20 in.)

   NOTICE:
     Install the oil pan assembly within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

1. Install the oil pan with the 22 bolts and 2 nuts.

   Torque:
     16 N*m{ 163 kgf*cm , 12 ft.*lbf }

1. Install the oil level gauge sensor with the 4 bolts.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

18. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

1. Face the crankshaft timing gear with timing mark 1 facing the forward.

1. Align the set key on the crankshaft with the key groove of the crankshaft timing gear.

1. Using SST and a hammer, tap in the timing gear.

   SST
     09223-00010

19. INSTALL SUPPLY PUMP GEAR

1. Install the supply pump with the 2 nuts.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

1. Temporarily install the pump gear with the nut.

   HINT:
     Fit the key (protrusion) of the supply pump to the key slot of the injection gear.

1. Install a new O-ring to the supply pump gear.

1. Install the supply pump gear set nut.

1. Using SST, tighten the nut.

   SST
     09960-10010 (09962-01000, 09963-01000)

   Torque:
     64 N*m{ 653 kgf*cm , 47 ft.*lbf }

20. INSTALL NO. 2 IDLE SUB GEAR

1. Mount the idler gear in a vise as shown in the illustration.

   NOTICE:
     Be careful not to damage the gear.

1. Install the gear spring.

1. Install the sub gear.

   HINT:
     Align the pins on the gears with the spring ends.

1. Install the wave washer.

1. Using snap ring pliers, install the snap ring.

1. Using SST, align the holes of the idler main gear and sub gears by turning the sub-gear clockwise, and install a service bolt.

   SST
     09960-10010 (09962-01000, 09963-00700)

   Recommended service bolt:

     Thread diameter | Thread pitch | Bolt length
     6.0 mm (0.23 in.) | 1.0 mm (0.03 in.) | Approx. 19 mm (0.75 in.)

1. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.

21. INSTALL NO. 1 IDLE GEAR

1. Install the gear shaft as shown in the illustration.

1. Align the "5" timing marks of the idle gear and crankshaft timing gear.

1. Using SST, turn the supply pump gear, and align the "4" timing marks of the idle gear and supply pump gear, and mesh the gears.

   SST
     09960-10010 (09962-01000, 09963-00700)

1. Face the thrust plate with the protrusion facing the forward.

1. Align the bolt holes, and install the thrust plate with the 2 bolts.

   Torque:
     50 N*m{ 510 kgf*cm , 37 ft.*lbf }

1. Remove the service bolt.

22. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

1. Align the set key with the key groove of the sensor plate.

1. Install the sensor plate, facing the cup side outward.

23. INSTALL TIMING GEAR CASE ASSEMBLY

1. Remove any old packing (FIPG) material.

1. Apply seal packing to the timing gear cover as shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     3 to 5 mm (0.12 to 0.20 in.)

   NOTICE:
     Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

1. Install a new O-ring to the timing gear case.

1. Install the timing gear cover with the 14 bolts and 2 nuts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

24. INSTALL WATER PUMP ASSEMBLY

1. Install a new gasket and the water pump with the 5 bolts and 2 nuts.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

25. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:

1. The cylinder head bolts are tightened in 3 progressive steps.
2. If any bolt is broken or deformed, replace it.

1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

1. Install and uniformly tighten the 18 cylinder head bolts, in several passes in the sequence shown in the illustration.

   Torque:
     85 N*m{ 867 kgf*cm , 63 ft.*lbf }

   Bolt length A:
     110 mm (4.33 in.)

   Bolt length B:
     167 mm (6.57 in.)
   If any of the cylinder head bolts does not meet the torque specification, replace it.

1. Mark the front of the cylinder head bolt with paint.

1. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

1. Finally, tighten the cylinder head bolts by an additional 90°.

1. Check that the painted mark is now facing rearward.

26. INSTALL CAMSHAFT

1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

   HINT:
     Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

1. Install the camshaft.

   1. Apply MP grease to the thrust portion of the camshaft.

   2. Place the camshaft on the cylinder head, facing the key groove upward.

   3. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

1. Remove any old packing (FIPG) material from the camshaft bearing cap.

1. Apply seal packing to the specified areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     4 mm (0.16 in.)

   NOTICE:
   1. Do not allow FIPG to contact the oil passage of the bearing cap.
   2. After applying FIPG, install the camshaft bearing caps within 3 minutes and fasten the bolts within 15 minutes.
   3. Do not start the engine for at least 2 hours after the installation.

   1. Install the 5 bearing caps in their proper locations.

   2. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

   3. Install and uniformly tighten the 10 bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
        19 N*m{ 194 kgf*cm , 14 ft.*lbf }

1. Install the camshaft oil seal.

27. INSPECT VALVE CLEARANCE

1. Check only the valves indicated.

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (Cold):

        Intake | Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) | 0.35 to 0.45 mm (0.014 to 0.018 in.)

      Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

1. Turn the crankshaft 360° to set the No. 4 cylinder to TDC / compression.

1. Check only the valves indicated.

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance:

        Intake | Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) | 0.35 to 0.45 mm (0.014 to 0.018 in.)

      Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

28. ADJUST VALVE CLEARANCE

1. Drain coolant.

1. Remove the fan shroud.

1. Remove the No. 1 timing belt cover.

1. Remove the timing belt.

1. Remove the camshaft timing pulley.

1. Remove the No. 1 timing belt idler.

1. Remove the No. 2 timing belt cover.

1. Remove the camshafts.

1. Remove the valve lifters.

1. Using a micrometer, measure the thickness of the removed lifter.

1. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

   Valve clearance:

     A | B | C
     Thickness of new lifter | Thickness of used lifter | Measured valve clearance

   Valve clearance (Cold):
     Intake A = B + (C - 0.25 mm (0.0098 in.))

   Valve clearance (Cold):
     Exhaust A = B + (C - 0.40 mm (0.00158 in.))

1. Select a new lifter with a thickness as close as possible to the calculated values.

   HINT:
     Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

1. Install the selected valve lifter.

   Intake valve clearance (Cold):
     0.20 to 0.30 mm (0.008 to 0.012 in.)

   EXAMPLE:
     The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) shim with a No. 40 lifter.

   New Lifter Thickness mm (in.):

     Shim No. | Thickness | Shim No. | Thickness | Shim No. | Thickness
     06 | 5.060 (0.1992) | 30 | 5.300 (0.2087) | 54 | 5.540 (0.2181)
     08 | 5.080 (0.2000) | 32 | 5.320 (0.2094) | 56 | 5.560 (0.2189)
     10 | 5.100 (0.2008) | 34 | 5.340 (0.2102) | 58 | 5.580 (0.2197)
     12 | 5.120 (0.2016) | 36 | 5.360 (0.2110) | 60 | 5.600 (0.2205)
     14 | 5.140 (0.2024) | 38 | 5.380 (0.2118) | 62 | 5.620 (0.2213)
     16 | 5.160 (0.2031) | 40 | 5.400 (0.2126) | 64 | 5.640 (0.2220)
     18 | 5.180 (0.2039) | 42 | 5.420 (0.2134) | 66 | 5.660 (0.2228)
     20 | 5.200 (0.2047) | 44 | 5.440 (0.2142) | 68 | 5.680 (0.2236)
     22 | 5.220 (0.2055) | 46 | 5.460 (0.2150) | 70 | 5.700 (0.2244)
     24 | 5.240 (0.2063) | 48 | 5.480 (0.2157) | 72 | 5.720 (0.2252)
     26 | 5.260 (0.2071) | 50 | 5.500 (0.2165) | 74 | 5.740 (0.2260)
     28 | 5.280 (0.2079) | 52 | 5.520 (0.2173) | - | -

   Exhaust valve clearance (Cold):
     0.35 to 0.45 mm (0.014 to 0.018 in.)

   EXAMPLE:
     The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a No. 42 lifter.

   New Lifter Thickness mm (in.):

     Shim No. | Thickness | Shim No. | Thickness | Shim No. | Thickness
     06 | 5.060 (0.1992) | 30 | 5.300 (0.2087) | 54 | 5.540 (0.2181)
     08 | 5.080 (0.2000) | 32 | 5.320 (0.2094) | 56 | 5.560 (0.2189)
     10 | 5.100 (0.2008) | 34 | 5.340 (0.2102) | 58 | 5.580 (0.2197)
     12 | 5.120 (0.2016) | 36 | 5.360 (0.2110) | 60 | 5.600 (0.2205)
     14 | 5.140 (0.2024) | 38 | 5.380 (0.2118) | 62 | 5.620 (0.2213)
     16 | 5.160 (0.2031) | 40 | 5.400 (0.2126) | 64 | 5.640 (0.2220)
     18 | 5.180 (0.2039) | 42 | 5.420 (0.2134) | 66 | 5.660 (0.2228)
     20 | 5.200 (0.2047) | 44 | 5.440 (0.2142) | 68 | 5.680 (0.2236)
     22 | 5.220 (0.2055) | 46 | 5.460 (0.2150) | 70 | 5.700 (0.2244)
     24 | 5.240 (0.2063) | 48 | 5.480 (0.2157) | 72 | 5.720 (0.2252)
     26 | 5.260 (0.2071) | 50 | 5.500 (0.2165) | 74 | 5.740 (0.2260)
     28 | 5.280 (0.2079) | 52 | 5.520 (0.2173) | - | -

1. Install the camshaft.

1. Install the No. 2 timing belt cover.

1. Install the No. 1 timing belt idler.

1. Install the camshaft timing pulley.

1. Install the timing belt.

1. Install the No. 1 timing belt cover.

1. Install the fan shroud.

1. Add engine coolant.

29. INSTALL NO. 2 TIMING BELT COVER

1. Apply seal packing (FIPG) to the specified areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
     After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

1. Install the No. 2 timing belt cover with the 4 bolts and nut.

   Torque:
     10 N*m{ 102 kgf*cm , 7 ft.*lbf }

30. INSTALL CAMSHAFT TIMING PULLEY

1. Install the camshaft timing pulley.

1. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

   Torque:
     98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }

31. INSTALL INJECTOR ASSEMBLY

NOTICE:

  Be sure to install the injector, holder clamp, washer and bolt in their original positions.

1. Install 4 new injection nozzle sheets to the cylinder head.

1. Apply a light amount of clean engine oil to 4 new O-rings.

1. Install the O-ring to each injector as shown in the illustration.

1. Insert the 4 injectors into the cylinder head.

   NOTICE:
   1. At this time, insert the injector until it touches the nozzle sheet surface.
   2. After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
   3. Always return an injector to the same place it was removed from.

1. Register injector compensation code (when replacing with a new injector).

1. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

   HINT:
     Apply a light amount of engine oil to the threads and under the heads of the clamp bolts.

   NOTICE:
   2. The fork portion of the nozzle holder clamp must be set to the injector.
   3. Before tightening the bolts, check that the nozzle holder clamp is set properly.
   4. To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at following step.
   5. When tightening the bolts, pay attention not to tilt the bolt and the clamp.
   6. Do not reuse the washer.
   7. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

1. Temporarily install the 4 injection pipes with the union nuts.

   HINT:
     To position the injectors, loosely tighten the union nut.

1. Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.
   If scratches or dents are present, replace the nozzle leakage pipe.

1. Set the leakage pipe and 5 new gaskets in place.

1. Apply a light amount of oil to the 4 hollow screws and union bolt.

1. Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

1. Tighten the 4 holder clamp bolts.

   Torque:
     22 N*m{ 224 kgf*cm , 16 ft.*lbf }

1. Tighten the 4 hollow screws in order from 1 to 4.

   Torque:
     16 N*m{ 163 kgf*cm , 12 ft.*lbf }

   NOTICE:
     If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

1. Tighten the union bolt.

   Torque:
     12.5 N*m{ 127 kgf*cm , 9 ft.*lbf }

   NOTICE:
     If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

1. Remove the 4 injection pipes.

32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

1. Remove any old seal packing (FIPG) material from the cylinder head.

1. Apply seal packing to the specific areas shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the belt cover within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 2 hours after installing the seal packing.

1. Install the gasket and cylinder head cover with the 10 bolts and 2 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install 4 new nozzle holder seals.

33. INSTALL NOZZLE HOLDER SEAL

1. Install 4 new holder seals.

34. INSTALL OIL FILLER CAP SUB-ASSEMBLY