CYLINDER BLOCK REASSEMBLY


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A015ZV9

      Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzles assembly with the 4 bolts.

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

  2. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A015Z8PE02

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

      Tech Tips

      Be sure that the end gap of the piston pin hole snap ring is not aligned with the service hole of the piston.

    2. A015YP1

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

    3. Coat the piston pin and connecting rod with engine oil.

    4. A0161LNE01

      Align the front marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the piston pin hole snap ring.

      Front Mark
      Item Front Mark
      Bank 1 piston 1 mark
      Bank 2 piston 2 marks

      Note

      For bank 1, assemble the piston and connecting rod so that the front mark of the piston and mark of the connecting rod face the same direction. For bank 2, assemble so that the front mark of the piston and mark of the connecting rod face the opposite direction.

      Tech Tips

      The piston and pin are a matched set.

    5. A0162E6

      Move the connecting rod back and forth on the piston pin. Check the fitting condition.

    6. Rotate the piston back and forth on the piston pin. Check the fitting condition.

    7. A015Z8PE02

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

      Tech Tips

      Be sure that the end gap of the piston pin hole snap ring is not aligned with the service hole of the piston.

  3. INSTALL PISTON RING SET


    1. A01612NE01

      Install the oil ring expander by hand.

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

    3. A01615TE01

      Using a piston ring expander, install the 2 compression rings so that the code marks are positioned as shown in the illustration.

      Tech Tips


      • Install the No. 1 compression ring with the code mark (1N) facing upward.

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

  4. INSTALL CRANKSHAFT BEARING


    1. A0162WZE14

      Clean the main journals and both surfaces of the bearings.

    2. Install the upper bearings.

      Note

      Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.


      1. A015ZCQE01

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

        Note


        • Do not apply engine oil to the bearing inner surfaces or main journal 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.

        • Do not allow coolant to come into contact with the bearing inner surface.

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

    3. A0162AGE01

      Install the lower bearings.

      Note


      • Be sure to install the selected bearings.

      • Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.


      1. Install the lower bearings to the bearing caps.

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

        Dimension A - B or B - A
        0 to 0.7 mm (0 to 0.0276 in.)

        Note


        • Do not apply engine oil to the bearing inner surfaces or bearing cap contact surfaces.

        • Do not allow coolant to come into contact with the bearing inner surface.

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

  5. INSTALL CRANKSHAFT THRUST WASHER SET


    1. A015YON

      Apply engine oil to the thrust washer set.

    2. Install the 4 thrust washers to the No. 3 journal position of the cylinder block and bearing cap with the oil grooves facing outward.

  6. INSTALL CRANKSHAFT


    1. Apply engine oil to the upper and lower bearings, then place the crankshaft on the cylinder block.

    2. A01623VE01

      Confirm the front marks and numbers of the main bearing caps, and install the bearing caps onto the cylinder block.

      Tech Tips

      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 bearing cap bolts.

    4. Temporarily install the 10 main bearing cap bolts to the inside positions.

    5. A015Z15E01

      Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal bearing cap bolts as a guide.

      Bolt length
      91 mm (3.58 in.)
    6. A016196

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

    7. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts.

    8. A015ZV3E01

      Temporarily install the 10 main bearing cap bolts to the outside positions.

      Bolt length
      79.5 mm (3.13 in.)

      Tech Tips

      Tighten the main bearing cap bolts in 2 progressive steps.

    9. Step 1:


      1. A015ZHVE02

        Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.

        Torque:
        61 N*m  { 622 kgf*cm, 45 ft.*lbf, for inside position }
        27 N*m  { 275 kgf*cm, 20 ft.*lbf, for outside position }

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

    10. Step 2:


      1. A0163BWE01

        Mark the front of each bearing cap bolt with paint.

      2. Tighten the bearing cap bolts another 90° in the order shown in step 1.

      3. Check that the painted marks are now at a 90° angle to the front.

    11. Check that the crankshaft turns smoothly.

    12. A015ZZBE01

      Install and uniformly tighten the 10 main bearing cap bolts and new 10 seal washers in several steps, in the sequence shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

    13. Check that the crankshaft turns smoothly.

  7. INSTALL CONNECTING ROD BEARING


    1. A0160WGE01

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

    2. Using a vernier caliper, measure the distance between the connecting rod and connecting rod cap edges, and each connecting rod bearing edge.

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • Do not apply engine oil to the bearing inner surfaces or connecting rod contact surfaces.

      • Do not allow coolant to come into contact with the bearing inner surface.

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

  8. INSTALL PISTON AND CONNECTING ROD


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

    2. A01631JE01

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

      Note

      Do not align the ring ends.

    3. A015Z2HE01

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

      Note

      Match the numbered connecting rod cap with the connecting rod.

      Front Mark
      Item Front Mark
      Bank 1 1 mark
      Bank 2 2 marks
    4. A01618LE02

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

      Front Mark
      Item Mark
      Bank 1 Front Side
      Bank 2 Rear Side

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

    6. Temporarily install the connecting rod cap bolts.

      Tech Tips

      The connecting rod cap bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. A0160AA

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

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. A015YWAE01

      Step 2:


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

      2. Tighten the connecting rod cap bolts another 90° as shown in the illustration in the order in step 1.

      3. Check that the painted marks are now at a 90° angle to the front.

      4. When using new connecting rod cap bolts, loosen each bolt once after tightening it 90° and perform steps 1 and 2 again.

    9. Check that the crankshaft turns smoothly.