Page 89 of 2248
G2M0185
3) Apply fluid packing to the mating surface of #1 and #3
cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring grooves,
oil passages, bearing grooves, etc.
B2M0088A
4) Temporarily tighten 10 mm cylinder block connecting
bolts in numerical order shown in Figure.
5) Tighten 10 mm cylinder block connecting bolts in
numerical order.
Tightening torque:
47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)
B2M0089A
6) Tighten 8 mm and 6 mm cylinder block connecting bolts
in numerical order shown in Figure.
Tightening torque:
1—7: 25±2 N⋅m
(2.5±0.2 kg-m, 18.1±1.4 ft-lb)
8: 6.4 N⋅m (0.65 kg-m, 4.7 ft-lb)
G2M0186
7) Install rear oil seal by using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER
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3. PISTON AND PISTON PIN (#1 AND #2)
B2M0128A
Tightening torque: N⋅m (kg-m, ft-lb)
T: 69±7 (7.0±0.7, 50.6±5.1)
G2M0188
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylinders face
upward.
(2) Using ST1, turn crankshaft so that #1 and #2 con-
necting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cylinders
and insert pistons in their cylinders by using ST2.
ST2 498747100 PISTON GUIDE
G2M0189
2) Installing piston pin
(1) Insert ST3 into service hole to align piston pin hole
with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE
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7. Cylinder Block
Page 91 of 2248
(2) Apply a coat of engine oil to piston pin and insert
piston pin into piston and connecting rod through ser-
vice hole.
G2M0190
(3) Install circlip.
CAUTION:
Use new circlips.
(4) Install service hole plug and gasket.
CAUTION:
Use a new gasket and apply a coat of fluid packing to
it before installation.
Fluid packing:
THREE BOND 1215 or equivalent
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7. Cylinder Block
Page 92 of 2248
4. PISTON AND PISTON PIN (#3 AND #4)
B2M0129A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4 (0.65, 4.7)
T2: 69±7 (7.0±0.7, 50.6±5.1)
Turn cylinder block so that #3 and #4 cylinders face
upward. Using the same procedures as used for #1 and #2
cylinders, install pistons and piston pins.
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E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP
B2M0124B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7)
T4: 72±3 (7.3±0.3, 52.8±2.2)
T5: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)
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7. Cylinder Block
Page 94 of 2248
G2M0084
1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent
G2M0194
5) Apply fluid packing to matching surfaces and install oil
separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0161
6) Install flywheel or drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.
G2M0076
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER
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7. Cylinder Block
Page 95 of 2248
B2M0390A
(2) Apply fluid packing to matching surface of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
Do not forget to install O-ring and seal when install-
ing oil pump.
Align flat surface of oil pump’s inner rotor with
crankshaft before installation.
G2M0628
9) Install engine coolant pump and gasket.
CAUTION:
Be sure to use a new gasket.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.
10) Install engine coolant pipe.
11) Install oil filter.
2. RELATED PARTS
1) Install cylinder head and intake manifold.
2) Install timing belt, camshaft sprocket and related parts.
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1. Engine Trouble in General
Numbers shown in the chart refer to the possibility of reason for the
trouble in order (“Very often”to“Rarely”)
1—Very often
2—Sometimes
3—Rarely
TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
POSSIBLE CAUSE
STARTER
2Defective battery-to-starter harness
3Defective starter switch
3Defective inhibitor switch
23Defective starter
BATTERY
1Poor terminal connection
1Run-down battery
2Defective charging system
1111111111 1Fuel injection system
Diagnostics II System.>
75
2-3DIAGNOSTICS
1. Engine Trouble in General