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БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

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  1. Click here

    INSTALL STUD BOLT

    Note:

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A01ENFWE06

      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
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    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
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    INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A01ES0SE01

      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. A01ES1ZE01

      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. A01ES0SE01

      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.

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    INSTALL PISTON RING SET


    1. A01ERV9E02

      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. A01EP40E01

      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
      A01EO1M Right Side
    3. A01ERXKE02

      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
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    INSTALL CRANKSHAFT BEARING

    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.

    Table 8. Text in Illustration
    *1 No. 1 and No. 5 Journal Bearings
    *2 No. 2, No. 3 and No. 4 Journal Bearings

    1. Clean each main journal and bearing.

    2. Install the upper bearing.


      1. A01EQ2YE02

        Install the upper bearing to the cylinder block.

        Table 9. Text in Illustration
        *1 Oil Groove
        *2 Oil Feed Hole
        *a CORRECT
        *b INCORRECT
        Note:
        • Do not apply engine oil to the bearings or 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 inner surface of the bearing.

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

    3. Install the lower bearings.


      1. A01ENSLE05

        Install the lower bearings to the crankshaft bearing caps.

        Table 10. Text in Illustration
        *1 Vernier Caliper
      2. Using a vernier caliper, measure the distance between the edge of the crankshaft bearing cap and the edge of the lower bearing.

        Dimension A - B or B - A
        0 to 0.7 mm (0 to 0.0276 in.)
        Note:
        • Do not apply engine oil to the bearings or contact surfaces.

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

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

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    INSTALL CRANKSHAFT THRUST WASHER SET


    1. A01EQX8E01

      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.

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    INSTALL CRANKSHAFT


    1. A01EP4OE02

      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. A01EPJ4E02

      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. A01EMZ3E01

      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. A01ERM8E01

      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. A01EN22E04

        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. A01ENULE02

      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.

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    INSTALL CONNECTING ROD BEARING


    1. A01ERW6E01

      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. A01EN3KE01

      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.)
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    INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01EPFJ

      С помощью индикатора часового типа измерьте осевой зазор, двигая коленчатый вал вперед и назад с помощью отвертки.

      Номинальный осевой зазор
      0,020 - 0,220 мм (0,000787 - 0,00866 дюйма)
      Максимально допустимый осевой зазор
      0,30 мм (0,0118 дюйма)

      Если осевой зазор превышает максимально допустимое значение, замените комплект упорных шайб.

      Номинальная толщина упорной шайбы
      2,44 - 2,49 мм (0,0961 - 0,0980 дюйма)

      При необходимости замените коленчатый вал.

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    INSTALL PISTON AND CONNECTING ROD


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

    2. A01ERXKE02

      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. A01EOE8E02

      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. A01EQGNE01

        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
        A01EO1M 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. A01EPV3

        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.