CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. B006YL8

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

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

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B0070YY

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

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

  3. INSTALL PISTON

    Tech Tips

    Perform inspection after repair after replacing the piston.



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

      Note

      Be 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.

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

      CAUTION:

      Be sure to wear protective gloves.

    3. Apply a light coat of engine oil to the piston, piston pin and connecting rod.

    4. B0071RDC01
      *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. B006YIIC01
      *1 Piston Pin Hole Snap Ring
      *a Cutout
      *b Protective Tape

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

      Note

      Be 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.

    6. B0070KS

      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.

        Tech Tips

        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.

        Tech Tips

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

  4. INSTALL PISTON RING SET

    Tech Tips

    Perform inspection after repair after replacing the piston and piston ring.



    1. B006X3FC01
      *1 Upper Side Rail
      *2 Oil Ring Expander
      *3 Lower Side Rail

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

    2. Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

      B006ZW0C02
      *a Press around the circumference *b Ring End
      *c Correct *d Incorrect (Ends of the oil ring expander are overlapping)

      Note


      • After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.

      • If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.

      • If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.

    3. B006YPQC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Code Mark
      *b Paint Mark
      B006Z38 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 1N Orange
      No. 2 Compression Ring 2N Pink

      Note

      Install the compression rings with the code marks facing upward.

    4. B006Z0YC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Upper Side Rail
      *5 Lower Side Rail
      *a Front Mark
      B006ZY0 Front of Engine

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

  5. INSTALL CRANKSHAFT BEARING


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

    2. B00718QC01
      *a Correct
      *b Incorrect

      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 or the contact surfaces.

      Tech Tips

      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.

    3. B006XVOC02
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the upper crankshaft bearing edge.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)
    4. B006X47C01
      *a Vernier Caliper

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

    5. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and 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 or the contact surfaces.

  6. INSTALL CRANKSHAFT THRUST WASHER


    1. B0071E6C01
      *a Oil Groove

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

    2. Apply engine oil to the crankshaft thrust washers.

  7. INSTALL CRANKSHAFT


    1. 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. B006XPWC01
      *a Front Mark

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

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

    5. Using a plastic hammer, lightly tap the crankshaft bearing caps to ensure a proper fit.

    6. Install the crankshaft bearing cap set bolts.

      Note

      The crankshaft bearing cap set bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. B007070N01

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

        Torque:
        61 N*m  { 622 kgf*cm, 45 ft.*lbf }

        Tech Tips

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

    8. Step 2:


      1. B0071KJC04
        *a Paint Mark
        *b 90°
        B006Z38 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° 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.

  8. INSTALL CONNECTING ROD BEARING


    1. B006ZHBC01
      *a Vernier Caliper

      Clean the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap, and both surfaces of the 2 connecting rod bearings.

    2. Install the 8 connecting rod bearings to the 4 connecting rods and 4 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.

  9. INSTALL PISTON WITH CONNECTING ROD


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

    2. B006Z0YC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Upper Side Rail
      *5 Lower Side Rail
      *a Front Mark
      B006ZY0 Front of Engine

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

    3. Confirm that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

      B006ZW0C02
      *a Press around the circumference *b Ring End
      *c Correct *d Incorrect (Ends of the oil ring expander are overlapping)

      Note


      • After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.

      • If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.

      • If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.

    4. B00705HC01
      *a Front Mark

      Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston with connecting rod 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 contact the No. 1 oil nozzle sub-assembly.

      • Match each connecting rod cap to the correct connecting rod.

    5. B0070ZTC01
      *a Front Mark

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

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

    7. Install the 8 connecting rod bolts.

      Note

      The connecting rod bolts are tightened in 2 progressive steps.

    8. Step 1:


      1. B006XZO

        Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts in several steps.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }
    9. B0071TFC01
      *a Paint Mark
      *b 90°
      B006Z38 Front of Engine

      Step 2:


      1. 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.

    10. Check that the crankshaft turns smoothly.

    11. Check the connecting rod thrust clearance.

      Click here

  10. INSTALL CYLINDER BLOCK WITH HEAD STRAIGHT SCREW PLUG (w/o Oil Cooler)


    1. B006WUD

      Using a 10 mm hexagon wrench, install the cylinder block with head straight screw plug and a new gasket to the cylinder block sub-assembly.

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

  11. INSTALL NO. 1 VENTILATION CASE

    Note

    Perform this procedure only when replacement of the No. 1 ventilation case is necessary.


    1. B006Z3T

      Install 3 new oil separator gaskets to the No. 1 ventilation case.

    2. B006Z4I

      Install the No. 1 ventilation case to the cylinder block sub-assembly with the 4 bolts.

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