CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL OIL JET


    1. A01VJRME01
      Text in Illustration
      *1 Cylinder block
      *a Upward
      *b Spool

      Install a new oil jet as shown in the illustration.

      Note

      Do not tap the tip of the oil jet.

      Tech Tips

      Press in the oil jet until the spool contacts the cylinder block.

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01VEJH

      Using a 5 mm socket 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 OIL CHECK VALVE SUB-ASSEMBLY


    1. A01VIZ5

      Install the oil check valve sub-assembly to the cylinder block.

      Text in Illustration
      A01VE7C Crankshaft Bearing Side

      Note


      • Make sure that the oil check valve sub-assembly is not tilted.

      • Install the oil check valve sub-assembly before installing the crankshaft bearing.

      • When installing the crankshaft bearing, make sure it does not interfere with the oil check valve sub-assembly.

  4. INSTALL PISTON

    Tech Tips

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

    A01VLCPE01

    1. Gradually heat a new connecting rod to 80°C (176°F) or more.

    2. Coat a new piston pin and pin holes in a new piston with engine oil.

    3. Align the front marks of the piston and connecting rod.

      Text in Illustration
      *a Front Mark

    4. Using SST, press in the piston pin.

      A01VGDKE01
      Text in Illustration
      *1 Piston Pin
      *2 Connecting Rod
      *3 Piston
      *a Front Mark
      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00090, 09221-00100, 09221-00150 )

      Note


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

      • With the connecting rod fully inserted into the piston end, press in the piston pin until it is flush with the piston surface.

    5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

  5. INSTALL PISTON RING SET

    A01VHA8E02
    Text in Illustration
    *1 Side Rail (Upper)
    *2 Expander Spacer
    *3 Side Rail (Lower)
    *a Expander Spacer and Side Rail Groove

    Tech Tips

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


    1. Install the expander spacer and 2 side rails by hand.

    2. A01VKWBE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a 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 (1R) facing upward.

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

    3. A01VE7YE01
      Text in Illustration
      *1 No. 1 Compression Ring and Side Rail (Upper)
      *2 No. 2 Compression Ring and Side Rail (Lower)
      *3 Expander Spacer
      A01VL3H Engine Front

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

  6. INSTALL CRANKSHAFT BEARING


    1. Install the 5 crankshaft bearings (upper) to the cylinder block.

      A01VIERE01
      Text in Illustration
      *a Correct
      *b Incorrect
      A01VE7C Engine Front

      Note


      • Align the oil holes on the crankshaft bearing and cylinder block.

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

    2. Install the 5 crankshaft bearings (lower).


      1. Install the 5 crankshaft bearings (lower) to the 5 crankshaft bearing caps.

      2. A01VEKWE01

        Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft bearing (lower) edge.

        Dimension (A - B)
        0.7 mm (0.0276 in.) or less

        Note

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

  7. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A01VIIJE05
      Text in Illustration
      *1 Oil Grooves

      Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.

    2. Apply engine oil to the crankshaft thrust washers.

  8. INSTALL CRANKSHAFT

    A01VEQNE04

    1. Apply engine oil to the crankshaft bearings (upper) and install the crankshaft on the cylinder block.

      Text in Illustration
      *a Number Mark
      A01VL3H Engine Front

    2. Apply engine oil to the crankshaft bearings (lower).

    3. Examine the number marks and install the crankshaft bearing caps on the cylinder block.

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

    5. A01VFXC

      Temporarily install the 10 crankshaft bearing cap set bolts.

    6. Step 1


      1. A01VFXCE04

        Install and uniformly tighten the 10 crankshaft bearing cap set bolts in the sequence shown in the illustration.

        Torque:
        30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    7. Step 2


      1. A01VGVXE01
        Text in Illustration
        *a Paint Mark
        A01VE7C Engine Front

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

      2. Further tighten the crankshaft bearing cap set bolts an additional 90° in the numerical order shown in the previous illustration.

    8. Check that the paint mark is now at a 90° angle to the front.

    9. Check that the crankshaft turns smoothly.

    10. Check the crankshaft thrust clearance Click here.

  9. INSTALL CONNECTING ROD BEARING

    A01VIF4

    1. Install the connecting rod bearing to the connecting rod and bearing cap.

    2. Using a vernier caliper, measure the distance between the connecting rod edge and connecting rod bearing (upper) edge.

      Dimension
      2.2 to 2.6 mm (0.0866 to 0.102 in.)

      Note

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

    3. A01VEEB

      Using a vernier caliper, measure the distance between the connecting rod bearing cap edge and connecting rod bearing (lower) edge.

      Dimension
      2.2 to 2.6 mm (0.0866 to 0.102 in.)

      Note

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

  10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    A01VE7YE01

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

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

      Text in Illustration
      *1 No. 1 Compression Ring and Side Rail (Upper)
      *2 No. 2 Compression Ring and Side Rail (Lower)
      *3 Expander Spacer
      A01VL3H Engine Front

      Note

      Do not align the ring ends.

    3. A01VFI9E05
      Text in Illustration
      *a Front Mark

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

      Note


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

      • Match the numbered connecting rod cap with the connecting rod.

    4. A01VJV4E08
      Text in Illustration
      *a Front Mark

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

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

    6. Install the connecting rod cap bolts.

      Note

      The connecting rod cap bolts should be tightened in 2 progressive steps.

    7. Step 1


      1. A01VLRPE02

        Using SST, install and alternately tighten the 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. A01VEQEE26
        Text in Illustration
        *a Paint Mark
        A01VE7C Engine Front

        Mark the front of the connecting rod cap bolts with paint.

      2. Further tighten the cap bolts an additional 90° as shown in the illustration.

    9. Check that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance Click here.