CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01VF58

      Using a 5 mm hexagon socket wrench, install the 3 No. 1 oil nozzle sub-assemblies with the 3 bolts.

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

  2. INSTALL PISTON WITH PIN SUB-ASSEMBLY

    Note

    If the piston pin is removed from the piston, replace the piston, piston pin and connecting rod subassembly with new ones.


    1. Gradually heat the small end of a new connecting rod to 80 to 90°C (176 to 194°F).

      CAUTION:

      Make sure not to burn yourself.

    2. Apply engine oil to the small end of the connecting rod sub-assembly and a new piston pin.

    3. A01VI32E01
      Text in Illustration
      *a Front Mark

      Align the front marks of the piston and connecting rod sub-assembly and insert the connecting rod sub-assembly into the piston.

    4. Using SST and a press, install the piston pin.

      A01VKQPE02
      Text in Illustration
      *1 Piston Pin *2 Connecting Rod Sub-assembly
      *3 Piston - -
      *a Front Mark *b Press
      *c 1.2 to 2.4 mm (0.0472 to 0.0945 in.) - -
      A01VL3H Rear Side - -
      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00130, 09221-00141, 09221-00150 )

      Note


      • Press in the piston pin from the front mark side of the piston.

      • Do not press in the piston pin at an angle.

    5. Hold the connecting rod sub-assembly and check that the piston moves smoothly.

  3. INSTALL PISTON RING SET


    1. A01VDQXE01
      Text in Illustration
      *1 Upper Side Rail
      *2 Expander Spacer
      *3 Lower Side Rail
      *a Expander Spacer Side Rail Groove

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

    2. A01VHIME01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      A01VL3H Upward

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

      Note


      • Install the No. 1 compression ring with the code mark (T1) and No. 2 compression ring with the code mark (T2) facing upward.

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

    3. A01VK27E02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Side Rail
      *4 Expander Spacer
      *5 Lower Side Rail
      *a Front Mark
      A01VL3H Engine Front

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

      Note

      Do not align the ring ends.

  4. INSTALL CRANKSHAFT BEARING


    1. Clean the main journals and both surfaces of the crankshaft bearings.

    2. Install the 4 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

      A01VFSME01
      Text in Illustration
      *a Correct *b Incorrect
      A01VL3H Engine Front - -

      Note


      • Do not apply engine oil to the crankshaft bearings or 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 engine coolant to come into contact with the crankshaft bearing inner surface.

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

    3. Install the 4 crankshaft bearings.


      1. A01VDRNE02

        Install the crankshaft bearings to the crankshaft bearing caps.

      2. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft bearing edge.

        Dimension (A - B)
        0.8 mm (0.0315 in.) or less

        Note

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

  5. INSTALL CRANKSHAFT


    1. Place the crankshaft on the cylinder block sub-assembly.

    2. Apply engine oil to the 2 crankshaft thrust washer uppers.

    3. A01VDRDE01
      Text in Illustration
      *a Oil Groove

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

    4. Apply engine oil to the crankshaft bearings.

    5. A01VL3W

      Examine the number marks and install the crankshaft bearing caps to the cylinder block sub-assembly.

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

    7. A01VF2Z

      Temporarily install the 8 crankshaft bearing cap set bolts.

    8. A01VF2ZE03

      Uniformly tighten the 8 crankshaft bearing cap set bolts in the order shown in the illustration.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

    9. Check that the crankshaft turns smoothly.

  6. INSPECT CRANKSHAFT THRUST CLEARANCE

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  7. INSTALL CONNECTING ROD BEARING


    1. A01VFO3E02
      *1 2.1 to 2.5 mm

      Install the connecting rod bearings to the connecting rod sub-assemblies and connecting rod bearing caps.

    2. Using a vernier caliper, measure the distance between the edges of the connecting rod sub-assemblies and connecting rod bearings.

      Standard dimension
      2.1 to 2.5 mm (0.0827 to 0.0984 in.)

      Note

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

    3. A01VIPWE02
      *1 2.1 to 2.5 mm

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

      Standard dimension
      2.1 to 2.5 mm (0.0827 to 0.0984 in.)

      Note

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

  8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD SUB-ASSEMBLY


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

    2. A01VK27E02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Side Rail
      *4 Expander Spacer
      *5 Lower Side Rail
      *a Front Mark
      A01VL3H Engine Front

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

      Note

      Do not align the ring ends.

    3. A01VHGZE02
      Text in Illustration
      *a Front Mark

      Using a piston ring compressor, push the correctly numbered piston sub-assembly and connecting rod sub-assembly into the cylinder with the front marks of the piston facing forward.

      Note


      • When inserting the piston sub-assembly with connecting rod sub-assembly, do not allow it to make contact with the No. 1 oil nozzle sub-assembly.

      • Match the numbered connecting rod bearing cap with the connecting rod sub-assembly.

    4. A01VI5TE04
      Text in Illustration
      *a Front Mark

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

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

    6. Install the connecting rod bolts.

      Note

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. A01VI69E03

        Using SST, alternately tighten the connecting rod bolts of the connecting rod cap in several steps.

        SST
        09205-16011
        Torque:
        15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    8. Step 2:


      1. A01VEJGE02
        Text in Illustration
        *a Paint Mark
        A01VL3H Engine Front

        Mark the front of the connecting rod bolts with paint.

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

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

    10. Check that the crankshaft turns smoothly.

  9. INSPECT CONNECTING ROD THRUST CLEARANCE

    Click here