CYLINDER BLOCK REASSEMBLY


  1. INSTALL STUD BOLT

    Note

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


    1. Using an E8 and E10 "TORX" socket wrenches, install the stud bolts.

      A01EK6YE02
      Torque:
      for stud bolt A
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      for stud bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01EJO8

      Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.

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

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01EMKY

      Using a 5 mm hexagon wrench, install the 2 oil nozzles with the 2 bolts.

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

  4. INSTALL PISTON


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

    2. Gradually heat the piston up to 80 to 90°C (176 to 194°F).

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

    4. A01EKLBE02
      Text in Illustration
      *1 Front Mark

      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.

      Tech Tips

      The piston and pin are a matched set.

    5. A01EIWDE02
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

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

    6. A01ELUG

      Check the fitting condition between the piston and piston pin.


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

        If abnormal movement is felt, replace the piston and pin as a set.

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

        If abnormal movement is felt, replace the piston and pin as a set.

  5. INSTALL PISTON RING SET


    1. A01EM7DE04
      Text in Illustration
      *1 Oil Ring
      *2 Oil Ring Expander
      *3 Coil Joint
      *4 Oil Ring End

      Install the oil ring expander and oil ring by hand.

      Tech Tips

      Arrange the oil ring ends and coil joint as shown in the illustration.

    2. A01ELQCE01

      Using a piston ring expander, install the 2 compression rings with the code mark positioned as shown in the illustration.

      Piston Ring Mark
      Item Code Mark Paint Mark
      No. 1 1N Blue
      No. 2 2N Orange

      Note

      Install the compression ring with the code mark facing upward.

  6. INSTALL CRANKSHAFT PULLEY KEY


    1. Install the 2 crankshaft pulley keys to the crankshaft.

  7. INSTALL CRANKSHAFT BEARING


    1. A01EL5FE02
      Text in Illustration
      *1 CORRECT
      *2 INCORRECT

      Clean the main journal and both surfaces of the bearing.

    2. Install the upper bearing to the cylinder block as shown in the illustration.

      Note


      • Do not apply engine oil to the bearings or their 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. A01EKDEE01

      Install the lower bearing onto the bearing cap.

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

      Standard 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 and the 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 CRANKSHAFT THRUST WASHER


    1. A01EJSVE03
      Text in Illustration
      *1 Oil Groove

      Apply engine oil to the thrust washers.

    2. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.

  9. INSTALL CRANKSHAFT


    1. A01EK9VE03
      Text in Illustration
      *1 Front Mark

      Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.

    2. Examine the front marks and numbers, and install the bearing caps onto the cylinder block with the front marks as shown in the illustration.

      Tech Tips

      The crankshaft bearing cap bolts are tightened in 3 progressive steps.

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

    4. Step 1:


      1. A01EK44E03

        Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    5. Step 2:


      1. Tighten the 10 bearing cap bolts again in the sequence shown in the illustration.

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

        If a crankshaft bearing cap bolt does not meet the specified torque, replace it.

    6. Step 3:


      1. A01EK70E03

        Mark the front of the bearing cap bolts with paint.

      2. Tighten the 10 bearing cap bolts 90° in the same sequence.

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

    7. Check that the crankshaft turns smoothly.

  10. INSTALL CONNECTING ROD BEARING


    1. A01ELO0E01

      Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings.

    2. Install the connecting rod bearings to the connecting rods and connecting rod caps.

    3. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing cap and connecting rod bearing.

      Standard 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 and the 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.

  11. INSTALL PISTON WITH CONNECTING ROD


    1. A01EKBQE03
      Text in Illustration
      *1 Front Mark
      *2 No. 1 Compression Ring
      *3 No. 2 Compression Ring
      *4 Oil Ring Rail
      *5 Oil Ring Expander
      *6 Front

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

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

    3. A01EKA0E02
      Text in Illustration
      *1 Front Mark

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

      Note

      When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod.

      Tech Tips

      The front mark is "1L" printed in raised letters.

    4. A01EK33E05
      Text in Illustration
      *1 Front Mark

      Check that the front mark of the connecting rod cap is facing in the correct direction.

      Note

      Match the numbered connecting rod cap with the connecting rod.

    5. A01EKO9

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

    6. Temporarily install the connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. Alternately tighten the connecting rod bolts in several steps.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. A01EMB6E03

      Step 2:


      1. Mark the front of the connecting rod bolts with paint.

      2. Tighten the bolts 90° as shown in the illustration.

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

    9. Check that the crankshaft turns smoothly.