CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the piston or piston ring set Click here.

PROCEDURE


  1. INSTALL STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. Using E8 and E10 "TORX" socket wrenches, install the 3 stud bolts.

      A01W39CE02
      Text in Illustration
      *a RH Side *b LH Side
      *c 20 mm (0.787 in.) *d 13 mm (0.512 in.)
      *e 35 mm (1.38 in.) *f 46 mm (1.81 in.)
      *g 19 mm (0.748 in.) *h 67 mm (2.64 in.)
      Torque:
      Stud Bolt (A)
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      Stud Bolt (B)
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01VZE6

      Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

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

  3. INSTALL PISTON


    1. Using a screwdriver, install a new piston pin hole snap ring (rear side) at one end of the piston pin hole.

      Tech Tips


      • Perform this procedure only when replacement of the piston pin hole snap ring (rear side) is necessary.

      • Tape the screwdriver tip before use.

    2. Gradually heat the piston to 80 to 90°C (176 to 194°F).

    3. Coat the piston, piston pin and connecting rod with engine oil.

    4. A01W03VE02
      Text in Illustration
      *a Cutout
      *b Front Mark

      Align the cutout of the piston and front mark of the connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the piston pin hole snap ring.

      Note

      Do not change the combination of the pistons and piston pins.

    5. A01W1K1E06
      Text in Illustration
      *1 Piston Pin Hole Snap Ring
      *a Cutout
      *b Protective Tape

      Using a screwdriver, install a new piston pin hole snap ring (front side) on the other side of the piston pin hole.

      Tech Tips


      • Be sure that the end gap of the piston pin hole snap ring is not aligned with the service hole front mark portion of the piston.

      • Tape the screwdriver tip before use.

    6. A01W02D

      Check the fitting condition between the piston and piston pin.


      1. Move the connecting rod back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and piston pin as a set.

      2. Rotate the piston back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, replace the piston and piston pin as a set.

        Tech Tips

        Perform "Inspection After Repair" after replacing the piston Click here.

  4. INSTALL PISTON RING SET


    1. A01W453E02
      Text in Illustration
      *a Upper Side Rail
      *b Oil Ring Expander
      *c Lower Side Rail
      *d Groove for Oil Ring Expander, Upper Side Rail and Lower Side Rail

      Install the oil ring expander, upper side rail and lower side rail by hand.

      Note

      Make sure that the oil ring expander ends do not overlap each other.

    2. A01W5K3E02
      Text in Illustration
      *a No. 1 Compression Ring
      *b No. 2 Compression Ring
      *c Code Mark
      *d Paint Mark
      B001O8N Upward

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown in the illustration.

      Piston Ring Mark
      Item Code Mark Paint Mark
      No. 1 Compression Ring - Yellow
      No. 2 Compression Ring A2 Blue

      Note


      • The No. 1 compression ring can be installed with either side facing upward.

      • Install the No. 2 compression ring with the code mark (A2) facing upward.

      • Paint marks can only be checked on new compression rings. When reusing compression rings, check each compression ring profile in order to install them to the correct positions.

      Tech Tips

      Perform "Inspection After Repair" after replacing the piston ring set Click here.

    3. A01W2XJE01
      Text in Illustration
      *a No. 1 Compression Ring
      *b No. 2 Compression Ring
      *c Upper Side Rail
      *d Oil Ring Expander
      *e Lower Side Rail
      *f Front Mark
      B001O8N Front Side

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

  5. INSTALL CRANKSHAFT PULLEY KEY


    1. Install the 2 crankshaft pulley keys to the crankshaft.

  6. INSTALL CRANKSHAFT BEARING


    1. A01W574E04
      Text in Illustration
      *a Correct
      *b Incorrect

      Clean the main journal and both surfaces of the crankshaft bearings and No. 2 crankshaft bearings.

    2. Install the 5 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

      Note


      • Do not apply engine oil to the crankshaft bearings and the contact surfaces.

      • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.

      • Do not allow coolant to come into contact with the crankshaft bearing inner surface.

      • If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

    3. A01VZX8E09
      Text in Illustration
      *a Vernier Caliper

      Install the 5 No. 2 crankshaft bearings onto the crankshaft bearing caps.

    4. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the No. 2 crankshaft bearing edge.

      Difference Between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • Do not apply engine oil to the No. 2 crankshaft bearings and the contact surfaces.

      • Do not allow coolant to come into contact with the No. 2 crankshaft bearing inner surface.

      • If any coolant comes into contact with the No. 2 crankshaft bearing inner surface, replace the No. 2 crankshaft bearing with a new one.

  7. INSTALL CRANKSHAFT THRUST WASHER


    1. A01W5PUE03
      Text in Illustration
      *a Oil Groove

      Apply engine oil to the crankshaft thrust washers.

    2. Install the 2 crankshaft thrust washers onto the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

  8. INSTALL CRANKSHAFT


    1. A01W0YSE02
      Text in Illustration
      *a Front Mark

      Apply engine oil to the crankshaft bearings, and place the crankshaft on the cylinder block sub-assembly.

    2. Apply engine oil to the No. 2 crankshaft bearings.

    3. Confirm the front marks and numbers, and install the 5 crankshaft bearing caps onto the cylinder block sub-assembly with the front marks as shown in the illustration.

      Tech Tips

      The crankshaft bearing cap bolts are tightened in 3 progressive steps.

    4. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.

    5. Step 1:


      1. A01W1IEE05

        Uniformly install and tighten the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    6. Step 2:


      1. Tighten the 10 crankshaft bearing cap bolts again in the order shown in the illustration.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

        If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

    7. Step 3:


      1. A01W5PZE18
        Text in Illustration
        *a Paint Mark
        B001OAO Engine Front

        Mark the front of the 10 crankshaft bearing cap bolts with paint.

      2. Tighten the 10 crankshaft bearing cap bolts by 90° in the order shown in the illustration.

      3. Check that the paint marks are now at a 90° angle to the front.

    8. Check that the crankshaft turns smoothly.

  9. INSTALL CONNECTING ROD BEARING


    1. A01W01ME10
      Text in Illustration
      *a Vernier Caliper

      Clean the connecting rod bearing contact surface of the connecting rod and connecting rod cap, and both surfaces of both connecting rod bearings.

    2. Install the 8 connecting rod bearings to the connecting rods and connecting rod caps.

    3. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the connecting rod cap and connecting rod bearing.

      Difference Between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • Do not apply engine oil to the connecting rod bearings and the contact surfaces.

      • Do not allow coolant to come into contact with the connecting rod bearing inner surface.

      • If any coolant comes into contact with the connecting rod bearing inner surface, replace the connecting rod bearing with a new one.

  10. INSTALL PISTON WITH CONNECTING ROD


    1. A01W2XJE01
      Text in Illustration
      *a No. 1 Compression Ring
      *b No. 2 Compression Ring
      *c Upper Side Rail
      *d Oil Ring Expander
      *e Lower Side Rail
      *f Front Mark
      B001O8N Front Side

      Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

    2. Position the piston rings so that the ring ends are as shown in the illustration.

      Tech Tips

      Regardless of the front mark, the piston rings are positioned correctly if their ends are positioned opposite of each other.

    3. A01W5NGE02
      Text in Illustration
      *a Front Mark

      Using a hammer handle and piston ring compressor, press the 4 piston with connecting rods into each cylinder with the front mark of the piston facing the engine front.

      Note

      When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the No. 1 oil nozzle sub-assembly does not interfere with the connecting rod.

    4. A01W528E01
      Text in Illustration
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing in the correct direction.

      Note

      Match the connecting rod cap with the connecting rod.

    5. A01W42W

      Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

    6. Temporarily install the 2 connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. Alternately tighten the 2 connecting rod bolts in several steps.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. A01VZM0E41
      Text in Illustration
      *a Paint Mark
      B001OAO Engine Front

      Step 2:


      1. Mark the front of the 2 connecting rod bolts with paint.

      2. Tighten the connecting rod bolts by 90° as shown in the illustration.

      3. Check that the paint marks are now at a 90° angle to the front.

    9. Check that the crankshaft turns smoothly.