CYLINDER BLOCK REASSEMBLY


  1. INSTALL CAMSHAFT BEARING


    1. A01CILRE03
      Text in Illustration
      *1 Notch
      *2 Oil Hole

      Be sure to face the notches of the No. 1 and No. 2 camshaft bearings and the oil holes of the No. 3 camshaft bearing in the correct direction.

    2. A01CGQIE03

      Using SST, install new camshaft bearings in the direction indicated by the arrow marks in the illustration.

      SST
      09215-00013   ( 09215-00021, 09215-00461 )
      09215-00101   ( 09215-00130, 09215-00141, 09215-00150, 09215-00161 )
      Text in Illustration
      A01CHW8 Front
      Journal Bearing Diameter
      Journal No. Inside Diameter Outside Diameter
      No. 1 57.0 mm (2.2441 in.) 60.0 mm (2.3622 in.)
      No. 2 56.8 mm (2.2362 in.) 59.8 mm (2.3543 in.)
      No. 3 56.6 mm (2.2283 in.) 59.6 mm (2.3465 in.)

      Note

      Install the No. 2, No. 1 and No. 3 camshaft bearings in order.

  2. INSTALL CONNECTING ROD SMALL END BUSH


    1. A01CI2N

      Uniformly chamfer one edge of the bush hole at the small end of the connecting rod.

      Tech Tips


      • Incorrect chamfering can cause the bush to run out-of-round, which may result in jamming during insertion.

      • Remove dust from the inner surface of the connecting rod hole.

    2. A01CHG4E03
      Text in Illustration
      *1 Groove
      *2 Oil Hole
      *3 Bush

      Mount a new bush on SST.

      SST
      S0940-21470
      S0948-11140
      S9191-08252
      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Tech Tips

      Align the oil holes in the bush with both grooves of SST, and make sure that oil holes will meet with the oil path in the connecting rod that comes from the big end bore in the rod.


      1. Apply fresh engine oil around the bush and guide.

    3. A01CI3YE04

      Prepare SST.

      SST
      S0940-21450
      S0948-11130
      S9233-10360

      1. Assemble the guide and press sub-assembly by inserting its pin into the guide, then secure them with the wing nut.

        Tech Tips

        Orient the letter W stamped on the guide above the pin.

      2. A01CIL0E05
        Text in Illustration
        *1 Connecting Rod
        *2 Guide
        *3 Press Sub-assembly

        Make sure to align both supporting surfaces of the guide and press sub-assembly on an even plane.

    4. A01CHG2E03
      Text in Illustration
      *1 Groove
      *2 Oil Hole

      Install the bush into the connecting rod. Position SST and bush so that the oil holes align with the oil path through the connecting rod.

      Tech Tips

      Before installing, fully coat the bore in the connecting rod with fresh engine oil.

    5. A01CGPX

      Inspect the bush position after installation.


      1. Make sure that the oil hole of the bush and the oil path of the connecting rod are suitably aligned.

        Tech Tips

        Misalignment can lead to insufficient lubrication, which may result in piston seizure.

      2. With a new piston pin inserted in the piston, make sure that the pin can be rotated by hand without looseness.

  3. INSTALL PISTON PIN HOLE SNAP RING


    1. A01CJCD

      Using snap ring pliers, install a new snap ring on one side of the piston hole.

  4. INSTALL PISTON

    Tech Tips

    Before assembling the piston with the connecting rod, check whether the piston is specified for this engine.

    Check should be performed using the engine compatible identification code on the top of the piston.

    Engine compatible identification code
    95

    1. A01CIM5

      Assemble the piston and connecting rod.


      1. Gradually heat the piston to approximately 50°C (122°F).

        CAUTION:

        Never touch the piston with your hand while it is hot.

      2. A01CIPRE05
        Text in Illustration
        *a Notch
        *b Matchmark

        Coat the piston pin with engine oil.

      3. Install the piston to the connecting rod with the notch of the piston facing in the same direction as the matchmark of the rod. Then, insert the piston pin.

      4. A01CGME

        Check that the piston and piston pin fit securely.

        Tech Tips

        Try to move the piston back and forth.

      5. A01CGP3

        Using snap ring pliers, install a new snap ring on the other side of the piston pin hole.

  5. INSTALL PISTON RING SET


    1. A01CI95

      Face the identification marks on the piston ring up, then using a piston ring expander, install them in the following order: the oil ring, 2nd ring and 1st ring.

      Tech Tips


      • Never change the combination of the coil and oil ring.

      • Connect the joint of the coil expander for the oil ring and install it inside the oil ring. Align the expander joint 180° opposite to the gap of the ring.

  6. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Install the No. 1 oil nozzle with the bolt.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

      Note


      • If an oil nozzle has been dropped or exposed to an impact, replace the nozzle with a new one.

      • Replace any deformed nozzle with a new one.

  7. INSTALL REAR CYLINDER BLOCK COVER


    1. Install the rear cylinder block cover with a new O-ring and the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  8. INSTALL CRANKSHAFT BEARING SET


    1. A01CHK3E03
      Text in Illustration
      *1 Oil Hole

      Align the oil groove of the bearing with the oil hole of the cylinder block, and push in the 5 upper bearings.

      Note

      Keep the back side of the bearing and the bearing surface free of foreign matter.

    2. A01CIBN

      Align the bearing with the crankshaft bearing cap, and push in the 5 lower bearings.

      Note

      Keep the back side of the bearing and the bearing surface free of foreign matter.

    3. Install the crankshaft.

    4. A01CI9ZE02
      Text in Illustration
      *1 Groove

      Insert the thrust washers into the clearance between the cylinder block and crankshaft with the oil groove facing outward.

    5. Install the main bearing caps to the cylinder block.

      Note

      Be sure to install the removed thrust washer to its original position.

    6. Apply a light coat of engine oil to the threads and under the cap bolt.

    7. A01CHKME03

      Temporarily tighten the bolts in several steps, in the sequence shown in the illustration.

    8. Tighten the bolts to the specified torque.

      Torque:
      60 N*m  { 610 kgf*cm, 44 ft.*lbf }
    9. A01CHU1E04
      Text in Illustration
      *a Paint Mark
      A01CHW8 Front

      Mark the front of the bearing cap bolts with paint.

    10. Retighten the bolts 60° and then an additional 60° as shown in the illustration.

    11. Check that each painted mark is now at a 120° angle to the front.

  9. INSTALL CYLINDER LINER


    1. A01CIQHE02
      Text in Illustration
      *a Position of Mark A, B or C

      Apply engine oil to the cylinder block inside bore.

      Tech Tips


      • When assembling the cylinder liner in the cylinder block, clearance can be set to 3 levels.

      • The upper surface and side surface of the cylinder block are stamped A, B or C. When using a new cylinder liner, insert a matching cylinder liner having the same symbol.

    2. A01CJ2DE02
      Text in Illustration
      *a Mark

      Align the marks of the cylinder liner and cylinder block.

      Tech Tips

      When reusing the cylinder liner, install it according to the marks made during the removal. When reusing the cylinder liner, misalignment with the cylinder block may concentrate stress on the thin part of the cylinder liner and the cylinder liner may break.

    3. Install the cylinder liner.

      Note

      Make sure to install the cylinder liner to its original location.

  10. INSPECT PROTRUSION OF CYLINDER LINER


    1. A01CI62E01

      Install SST onto the cylinder block.

      SST
      S0942-01460

    2. Tighten the center bolt to the specified torque below to set SST in the proper installation position.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. A01CGUTE04
      Text in Illustration
      *a Pressure: 4903 N (500 kgf, 1102.5 lbf)
      *b Protrusion

      Using a dial indicator, measure the protrusion of the cylinder liner.

      Standard protrusion
      0.01 to 0.08 mm (0.000394 to 0.00315 in.)
      Maximum protrusion
      0.08 mm (0.00315 in.)

      If the protrusion is greater than the maximum, replace the cylinder liner.

  11. INSTALL CONNECTING ROD BEARING

    Note


    • A01CHKN

      When reusing the bearing, make sure to reassemble the removed bearing as it was originally installed.

    • Install the bearing with the oil hole on the connecting rod side and install the bearing without the oil hole on the cap side.

    • Match the bearing protrusion with the notch of the connecting rod or cap.

    • Keep the back side of the bearing and bearing surface of the bearing cap free of foreign matter.

  12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01CIPDE01
      Text in Illustration
      *1 Mark
      *2 Top Ring
      *3 2nd Ring
      *4 Oil Ring

      Using a piston ring compressor and a hammer handle, insert the piston with connecting rod assembly into the cylinder block.

      Note


      • Position the piston ring end gaps an even distance apart from each other as shown in the illustration. Do not align the ring end gaps.

      • Before installation, apply engine oil to the piston pin, piston ring, cylinder liner and connecting rod bearing.

      • Do not damage the inside of the liner.


      1. A01CJ83E02
        Text in Illustration
        *1 Mark
        *2 Tappet Chamber

        Make sure that the mark on the piston is at the tappet chamber side.

    2. Install the bearing cap to the connecting rod with the front mark facing in the correct direction.

    3. Uniformly install and tighten the bolts to the specified torque in several steps.

      Torque:
      30 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A01CJHQE02
      Text in Illustration
      *a Paint
      A01CHW8 Front

      Mark the front side of the bolt head with paint as shown in the illustration.

    5. Retighten the bolts 60°.

    6. Perform step (e) again.

    7. Check that each painted mark is now at a 120° angle to the front.