БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

INSTALL STUD BOLT

1. 

   Using an E8 "TORX" socket wrench, install the stud bolts.

   for stud bolt A
   20 N*m	199 kgf*cm	14 ft.*lbf
   for stud bolt B
   9.0 N*m	92 kgf*cm	80 in.*lbf

   Table 1. Text in Illustration

   *a

   Upper Side

   *b

   Lower Side

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

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

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL PISTON WITH PIN SUB-ASSEMBLY

1. 

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

   Table 2. Text in Illustration

   *1	Service Cutout

   Tip:

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

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

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

4. 

   Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the pin comes into contact with the snap ring.

   Table 3. Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *1	Front Mark

   Note:

   For the LH side, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For the RH side, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides.

   Tip:

   The piston and pin are a matched set.

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

6. 

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

   Table 4. Text in Illustration

   *1	Service Cutout

   Tip:

   Be sure that the end gap of the snap ring is not aligned with the cutout of the piston.

INSTALL PISTON RING SET

1. 

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

   Table 5. Text in Illustration

   *1	Upper Side Rail
   *2	Oil Ring Expander
   *3	Lower Side Rail

2. 

   Using a piston ring expander, install the 2 compression rings with the paint mark on the right side.

   Paint Mark
   Item Paint Mark No. 1 compression ring Yellow No. 2 compression ring Green

   Table 6. Text in Illustration

   *1	Paint Mark
   *2	No. 1 Compression Ring
   *3	No. 2 Compression Ring
   	Right Side

3. 

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

   Table 7. Text in Illustration

   *1	Front Mark
   *2	Upper Side Rail
   *3	Lower Side Rail
   *4	No. 1 Compression Ring
   *5	No. 2 Compression Ring

INSTALL CRANKSHAFT THRUST WASHER SET

1. 

   Apply engine oil to the thrust washer set.

   Table 11. Text in Illustration

   *1	Oil Groove

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.

INSTALL CRANKSHAFT

1. 

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

   Table 12. Text in Illustration

   *1	Number Mark

2. Confirm the front marks and numbers of the main bearing caps and install the bearing caps to 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 bearing cap bolts.

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

5. 

   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.) and partially tighten the 2 inner bearing cap bolts.

   Bolt length
   91 mm (3.58 in.)

   Table 13. Text in Illustration

   *a	Less than 6 mm

6. 

   Using a plastic-faced 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 10 main bearing cap bolts.

8. 

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

   Bolt length
   79.5 mm (3.13 in.)

9. Tighten the main bearing cap bolts.

   Tip:

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

   
   
   1. 

      Step 1:

      Uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.

      for inner bolts
      61 N*m	622 kgf*cm	45 ft.*lbf
      for outer bolts
      27 N*m	275 kgf*cm	20 ft.*lbf

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

   2. Mark the front of the bearing cap bolts with paint.

   3. Step 2:

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

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

10. Check that the crankshaft turns smoothly.

11. 

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

    45 N*m

    459 kgf*cm

    33 ft.*lbf

12. Check that the crankshaft turns smoothly.

INSTALL CONNECTING ROD BEARING

1. 

   Install the bearing to the connecting rod cap.

   Table 14. Text in Illustration

   *1	Vernier Caliper
   *2	Connecting Rod Cap
   *3	Connecting Rod Bearing

   Note:
   

   • Clean the contact surfaces of the bearing and connecting rod cap.

   • Do not apply engine oil to the bearing or the surface it contacts.

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

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

3. 

   Install the bearing to the connecting rod.

   Table 15. Text in Illustration

   *1	Vernier Caliper
   *2	Connecting Rod
   *3	Connecting Rod Bearing

   Note:
   

   • Clean the contact surface of the bearing and connecting rod.

   • Do not apply engine oil to the bearing or the surface it contacts.

4. Using a vernier caliper, measure the distance between the connecting rod edge and connecting rod bearing edge.

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

INSTALL PISTON AND CONNECTING ROD

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

2. 

   Check the positions of the piston ring ends.

   Table 16. Text in Illustration

   *1	Front Mark
   *2	Upper Side Rail
   *3	Lower Side Rail
   *4	No. 1 Compression Ring
   *5	No. 2 Compression Ring

   Note:

   Do not align the ring ends.

   Tip:

   The expander ends can be placed anywhere.

3. 

   Using a hammer handle and piston ring compressor, press a piston and connecting rod assembly into each cylinder with the front mark of the piston facing forward.

   Table 17. Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *1	Front Mark

4. Place the connecting rod cap on the connecting rod.

   
   
   1. 

      Match the numbered connecting rod cap with the connecting rod.

      Table 18. Text in Illustration

      *A	for Bank 1
      *B	for Bank 2
      *1	Front Mark
      	Front

   2. Check that the front mark of the connecting rod cap is facing the proper direction.

      Front Mark
      Item Front Mark LH Front Side RH Rear Side

5. Install the connecting rod cap bolts.

   Tip:

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

   
   

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

   2. Temporarily install the connecting rod cap bolts.

   3. 

      Step 1:

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

      40 N*m

      408 kgf*cm

      30 ft.*lbf

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

   5. Step 2:

      Tighten the cap bolts 90°.

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

6. Check that the crankshaft turns smoothly.