CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

Click here

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. A01OAR2C02
      *a 46 mm (1.81 in.)
      *b 19 mm (0.748 in.)
      *c 67 mm (2.64 in.)

      Using an E10 "TORX" socket wrench, install the stud bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01WXKO

      Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzle sub-assemblies with the 4 bolts.

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

      Note

      Install the No. 2 oil nozzle sub-assemblies to the same place they were removed from.

  3. INSTALL PISTON

    Tech Tips

    Perform "Inspection After Repair" after replacing the piston.

    Click here


    1. A01OBK7C03
      *a Protective Tape
      *b Piston Pin Hole Snap Ring (Rear Side)

      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 between 80 and 90°C (176 and 194°F).

    3. Apply engine oil to the piston, piston pin and connecting rod.

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

    4. A01OCIZC02
      *a Front Mark

      Align the front marks of the piston and 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 (rear side).

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

      Note

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

  4. INSTALL PISTON PIN HOLE SNAP RING


    1. A01OC6SC04
      *a Cutout
      *b Piston Pin Hole Snap Ring (Front Side)
      *c Protective Tape

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

      Note

      Make sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston.

      Tech Tips

      Tape the screwdriver tip before use.

  5. INSPECT PISTON WITH CONNECTING ROD


    1. Check the fitting condition between the piston, piston pin and connecting rod.


      1. A01ODKS

        Move the connecting rod back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, check the piston pin oil clearance.

        Click here

  6. INSTALL PISTON RING SET

    Tech Tips

    Perform "Inspection After Repair" after replacing the piston and piston ring.

    Click here


    1. A01OAIWC05
      *a Groove for Oil Ring Expander, Upper Side Rail and Lower Side Rail
      *b Upper Side Rail
      *c Oil Ring Expander
      *d Lower Side Rail

      Install the oil ring expander by hand.

    2. Install the upper side rail and lower side rail by hand.

      Note

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

      Tech Tips

      Install the oil expander ring so that its end with the white paint mark is positioned to the right of the piston.

    3. A01OA3WC02
      *a Paint Mark
      *b Code Mark
      *c No. 1 Compression Ring
      *d No. 2 Compression Ring
      B004FMB 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 Code Mark
      Item Code Mark Paint Mark
      No. 1 Compression Ring 1NA Blue
      No. 2 Compression Ring 2N Green

      Note

      Install the No. 1 compression ring and No. 2 compression ring with the code marks facing upward.

    4. A01OD8HC03
      *a No. 1 Compression Ring and Upper Side Rail
      *b Oil Ring Expander
      *c No. 2 Compression Ring and Lower Side Rail
      *d Front Mark
      B004FMB Front of Engine

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

      Tech Tips


      • Regardless of the piston front mark, the positional relation of all ring ends must be maintained.

      • The ends of the oil ring expander can also be positioned at "A".

  7. INSTALL CRANKSHAFT BEARING


    1. Clean the main journals and both surfaces of the No. 1 crankshaft bearings and No. 2 crankshaft bearings.

      Tech Tips

      The colors of the No. 1 crankshaft bearings and No. 2 crankshaft bearings differ depending on the installation position.

      Installation Journal Position No. 1 Crankshaft Bearing No. 2 Crankshaft Bearing
      No. 1 Black Black
      No. 2 Silver Silver
      No. 3 Black Silver
      No. 4 Silver Silver
      No. 5 Silver Black

    2. Apply engine oil to the No. 1 crankshaft bearings and No. 2 crankshaft bearings or the main journals.

      Note

      Do not apply engine oil to the back of the No. 1 crankshaft bearings or No. 2 crankshaft bearings.

    3. A01OBUNC03
      *a Correct
      *b Incorrect
      *c Oil Feed Hole
      *d Oil Groove

      Install the 5 No. 1 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

      Note


      • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the No. 1 crankshaft bearing. The amount visible on each side of the oil feed holes should be equal.

      • Do not allow coolant to come into contact with the No. 1 crankshaft bearing inner surface.

      • If any coolant comes into contact with the No. 1 crankshaft bearing inner surface, replace the No. 1 crankshaft bearing with a new one.

    4. A01OCAWC06
      *a Crankshaft Bearing Cap
      *b No. 2 Crankshaft Bearing
      *c Vernier Caliper

      Install the 5 No. 2 crankshaft bearings to the No. 1 crankshaft bearing caps and No. 2 crankshaft bearing cap.

    5. 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 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.

  8. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. Apply engine oil to the 2 upper crankshaft thrust washers.

    2. A01O9ANC03
      *a Oil Groove
      *b Identification Groove

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

      Note

      Check that the identification grooves are positioned as shown in the illustration.

  9. INSTALL CRANKSHAFT


    1. Apply engine oil to the No. 1 crankshaft bearings, and install the crankshaft to the cylinder block sub-assembly.

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

    3. A01O9LVC06
      *a Front Mark
      *b No. 1 Crankshaft Bearing Cap
      *c No. 2 Crankshaft Bearing Cap

      Confirm the front marks and numbers, and install the 4 No. 1 crankshaft bearing caps and No. 2 crankshaft bearing cap to the cylinder block sub-assembly with the front marks positioned as shown in the illustration.

      Note

      There are 2 types of crankshaft bearing caps. Be sure to install them to their correct positions.

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

      Tech Tips

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

    5. Step 1:


      1. A01WXPYN02

        Uniformly install and tighten the 10 crankshaft bearing cap set 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. Further tighten the 10 crankshaft bearing cap set bolts in the order shown in the illustration.

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

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

    7. Step 3:


      1. A01OBRWC02
        *a Paint Mark
        *b 90°
        B004FMB Front of Engine

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

      2. Tighten the 10 crankshaft bearing cap set bolts 90° in the same order shown in step1.

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

    8. Check that the crankshaft turns smoothly.

  10. INSTALL CONNECTING ROD BEARING


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

    2. A01O9T5C18
      *1 Connecting Rod Bearing
      *a Vernier Caliper
      *b Connecting Rod Cap

      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 or 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.

  11. INSTALL PISTON WITH CONNECTING ROD


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

    2. A01OD8HC03
      *a No. 1 Compression Ring and Upper Side Rail
      *b Oil Ring Expander
      *c No. 2 Compression Ring and Lower Side Rail
      *d Front Mark
      B004FMB Front of Engine

      Check the position of the piston ring ends again.

      Tech Tips


      • Regardless of the piston front mark, the positional relation of all ring gaps must be maintained.

      • The ends of the oil ring expander can also be positioned at "A".

    3. A01O9BNC02
      *a Front Mark

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

      Note

      When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the connecting rod does not interfere with the No. 2 oil nozzle sub-assembly.

    4. A01O9VTC03
      *a Front Mark

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

      Note

      Match the connecting rod cap with the connecting rod.

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

    6. Using a 12 mm bi-hexagon wrench, 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. Step 2:


      1. A01OBERC03
        *a Paint Mark
        *b 90°
        B004FMB Front of Engine

        Mark the front of the connecting rod bolts with paint.

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

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

    9. Check that the crankshaft turns smoothly.