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CYLINDER BLOCK REASSEMBLY

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  1. Click here

    INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A017D1N

      Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assembly.

      9.0 N*m 92 kgf*cm 80 in.*lbf
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    INSTALL PISTON SUB-ASSEMBLY WITH PIN


    1. A017FQOE01

      Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.

      Tip:

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

    2. A017BJB

      Gradually heat the piston to approximately 80°C (176°F).

    3. Coat the piston pin with engine oil.

    4. A017DXOE01

      Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      Tip:

      The piston and pin are a matched set.

    5. A017C27

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

    6. A017CWCE02

      Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

      Tip:

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

  3. Click here

    INSTALL PISTON RING SET


    1. Install the oil ring expander and 2 side rails by hand.

    2. A017CLAE04

      Using a piston ring expander, install the compression ring as shown in the illustration.

    3. A017E54E01

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

      Note:

      Do not align the ring ends.

  4. Click here

    INSTALL CRANKSHAFT BEARING


    1. A017DF3E08

      Clean the main journal and both surfaces of the bearing.

      Note:

      Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

    2. A017DOYE05

      Install the upper crankshaft bearing.


      1. Install the upper crankshaft bearings to the cylinder block as shown in the illustration.

        Note:

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

        • Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

    3. A017B13E06

      Install the lower crankshaft bearing.


      1. Install the lower crankshaft bearings to the crankshaft bearing caps.

      2. Using vernier calipers, measure the distance between the crankshaft bearing cap's edge and the lower crankshaft bearing's edge.

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

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

  5. Click here

    INSTALL CRANKSHAFT THRUST WASHER SET


    1. Apply engine oil to the crankshaft thrust washer.

    2. A017BYLE02

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

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    INSTALL CRANKSHAFT


    1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

    2. A017DVYE02

      Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block.

      Tip:

      A number is marked on each main bearing cap to indicate the installation position.

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

    4. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

    5. A017CB0E02

      Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide.

      Bolt length
      100 to 102 mm (3.94 to 4.02 in.)
    6. A017C0B

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

    7. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.

    8. A017FSRE01

      Install the 8 crankshaft bearing cap bolts to the outside positions.

    9. Install the crankshaft bearing cap bolts.

      Tip:

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

    10. Step 1


      1. A017DDCE02

        Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

        61 N*m 622 kgf*cm 45 ft.*lbf

        If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it.

    11. Step 2


      1. A017EBYE03

        Mark the front of the bearing cap bolts with paint.

      2. Retighten the bearing cap bolts 90° in the sequence shown in the preceding illustration.

      3. Check that the painted mark is now at a 90° angle to the front of the engine.

    12. A017CODE05

      Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

      52 N*m 525 kgf*cm 38 ft.*lbf
      Bolt length
      Item Length
      Bolt A 45 mm (1.77 in.)
      Except bolt A 30 mm (1.18 in.)

    13. Check that the crankshaft turns smoothly.

    14. Check the crankshaft thrust clearance (Click here).

  7. Click here

    INSTALL CONNECTING ROD BEARING


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

    2. A017DBUE02

      Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.

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

      Do not apply engine oil to the bearings and the contact surfaces.

  8. Click here

    INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A017E54E01

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

      Note:

      Do not align the ring ends.

    3. A017FZ6E01

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

      Note:

      Match the numbered connecting rod cap with the connecting rod.

    4. A017DZFE02

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

    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 cap bolts.

      Tip:

      The connecting cap bolts are tightened in 2 progressive steps.

    7. Step 1


      1. A017CST

        Install and alternately tighten the bolts of the connecting rod cap in several steps.

        25 N*m 255 kgf*cm 18 ft.*lbf

    8. Step 2


      1. A017FPME07

        Mark the front side of each connecting cap bolt with paint.

      2. Retighten the cap bolts 90° as shown in the illustration.

      3. Check the painted mark is now at a 90° angle to the front.

    9. Confirm that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance (Click here).