Part 2

ENGINE UNIT

REASSEMBLY (STEPS 10 - 29)

10. INSTALL CONNECTING ROD CAP BOLTS

HINT:
- The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
- If any one of the connecting rod cap bolts is broken or deformed, replace it.





a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
b) Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.





c) Mark the front of the connecting cap bolt with paint.
d) Retighten the cap bolts by 90° as shown.
e) Check that the painted mark is now at a 90° angle to the front.
f) Check that the crankshaft turns smoothly.

11. INSTALL CONNECTING ROD THRUST CLEARANCE
12. INSTALL REAR OIL SEAL RETAINER





a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the oil seal retainer and cylinder block.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.

b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
^ Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.
^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.





c) Install a new O-ring to the cylinder block.
d) Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)

13. INSTALL ENGINE COOLANT DRAIN UNIONS





a) Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent





b) Install the 2 drain unions.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

14. INSTALL OIL PUMP
15. INSTALL OIL STRAINER
16. INSTALL NO. 1 OIL PAN
17. INSTALL OIL PAN BAFFLE PLATE
18. INSTALL NO. 2 OIL PAN
19. INSTALL WATER PUMP
20. INSTALL ENGINE MOUNTING BRACKETS
a) Install the mounting bracket with the 4 bolts. Install the 2 mounting brackets.
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)

21. INSTALL ENGINE WIRE TO LH SIDE OF CYLINDER BLOCK





a) Install the brackets on the engine wire with the 2 bolts.
b) Install the engine wire cover with the 2 bolts.

22. INSTALL OIL COOLER PIPE BRACKET FOR A/T
a) Install the bracket with the bolt.

23. INSTALL VVT SENSORS
24. INSTALL KNOCK SENSORS
25. INSTALL STARTER
26. INSTALL WATER BYPASS PIPE





a) Install a new O-ring to the water bypass pipe.
b) Apply soapy water to the O-ring.
c) Push in the water bypass pipe end into the pipe hole of the water pump.
d) Install the water bypass pipe with the bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
e) Install the wire clamp to the bracket of the water bypass pipe.

27. INSTALL CYLINDER HEADS
28. INSTALL TIMING BELT AND PULLEYS
29. DISCONNECT ENGINE TO ENGINE STAND