CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Note

Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block, connecting rod and other parts.

PROCEDURE


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  2. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A004QHCE05
      Text in Illustration
      *1 Snap Ring
      *a Service Hole Cutout Portion

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

      Tech Tips

      Make sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston sub-assembly.

    2. Coat the piston pin with engine oil.

    3. A004TL5E03
      Text in Illustration
      *a Matchmark

      Align the matchmarks of the piston sub-assembly and connecting rod sub-assembly, install the connecting rod sub-assembly to the piston sub-assembly and push in the piston pin with your thumb.

      Tech Tips

      The piston and pin are a matched set.

    4. A004QHCE06
      Text in Illustration
      *a Service Hole Cutout Portion

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

      Tech Tips

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

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

  3. INSTALL PISTON RING SET


    1. A004SP2

      Install the oil ring expander by hand.

    2. A004PTTE02
      Text in Illustration
      *a Coil Joint
      *b Oil Ring End

      Using a piston ring expander, install the oil ring rail.

      Tech Tips

      Make sure the end gap of the oil ring faces in the opposite direction of the coil joint.

    3. A004PQ4E02
      Text in Illustration
      *a Code Mark (TOP)
      *b Plain Rectangular Compression Ring
      *c Taper-faced Compression Ring

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the code marks are positioned as shown in the illustration.

      Code Mark
      Item Specified Condition
      No. 1 compression ring TOP
      No. 2 compression ring
      Oil ring rail

      Tech Tips

      Install the No. 1 compression ring, No. 2 compression ring and oil ring rail with the code mark facing upward.

    4. A004PGIE02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Rail
      *4 Oil Ring Expander
      *a Front
      *b Front Mark

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

      Note

      Do not align the ring ends.

  4. INSTALL CONNECTING ROD BEARING

    Note

    Apply engine oil to the inner surface of each connecting rod bearing (the surface which contacts the crankshaft assembly), but not to the outer surface (the surface which contacts the connecting rod sub-assembly or connecting rod cap).


    1. A004PA9

      Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.

      Note


      • Clean the backside of the connecting rod bearing and the connecting rod bearing surface of the connecting rod sub-assembly.

      • Make sure that the surface of the fractured connecting rod does not have foreign matter or become damaged.

      • Do not contact the surface of the fractured connecting rod wearing gloves.

  5. INSTALL CRANKSHAFT BEARING

    Note


    • Apply engine oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft assembly), but not to the outer surface (the surface which contacts the crankshaft bearing cap or cylinder block).

    • When replacing a crankshaft bearing, also replace the corresponding upper or lower bearing.


    1. Clean each main journal and crankshaft bearing.

    2. A004PDDE03
      Text in Illustration
      *a Claw

      Align the crankshaft bearing claw with the claw groove of the cylinder block, and push in the 4 upper crankshaft bearings to install them.

      Note


      • Clean the contact surface of the crankshaft bearing and cylinder block.


      • Apply engine oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft assembly), but not to the outer surface (the surface which contacts the cylinder block).


      • Make sure both sides of the oil groove in the cylinder block are visible through the oil feed holes in the crankshaft bearing. Make sure the amount visible on each side of the holes is equal.

    3. A004NIOE03
      Text in Illustration
      *a Claw

      Align the crankshaft bearing claw with the claw groove of the cylinder block, and push in the No. 3 upper crankshaft bearing to install the bearing.

      Note


      • Clean the contact surface of the crankshaft bearing and cylinder block.


      • Apply engine oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft assembly), but not to the outer surface (the surface which contacts the cylinder block).


      • Make sure both sides of the oil groove in the cylinder block are visible through the oil feed holes in the crankshaft bearing. Make sure the amount visible on each side of the holes is equal.

    4. A004RRHE02
      Text in Illustration
      *a Claw

      Align the crankshaft bearing claw with the claw groove of the crankshaft bearing cap, and push in the 4 lower crankshaft bearings to install the bearing.

      Note


      • Clean the contact surface of the crankshaft bearing and crankshaft bearing cap.


      • Apply engine oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft assembly), but not to the outer surface (the surface which contacts the crankshaft bearing cap).

    5. A004ROHE01
      Text in Illustration
      *a Claw

      Align the crankshaft bearing claw with the claw groove of the crankshaft bearing cap, and push in the No. 3 lower crankshaft bearing to install the bearing.

      Note


      • Clean the contact surface of the crankshaft bearing and crankshaft bearing cap.


      • Apply engine oil to the inner surface of each crankshaft bearing (the surface which contacts the crankshaft assembly), but not to the outer surface (the surface which contacts the crankshaft bearing cap).

  6. INSTALL CRANKSHAFT ASSEMBLY


    1. Apply engine oil to the crankshaft bearings, and then place the main bearing cap on the cylinder block.

      Note

      Do not apply oil to the bearing cap bolt hole.

    2. A004TPWE01

      Set the crankshaft bearing caps on the crankshaft assembly as shown in the illustration.

      Text in Illustration
      A004NPW Front

      Tech Tips

      Make sure the crankshaft bearing caps are placed in the proper position and direction by checking the numbers on the caps.

    3. Install new crankshaft bearing cap bolts.

      Note

      Do not reuse the bearing cap bolt.

      Tech Tips

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

    4. A004S5ZE04

      Step 1:


      1. Uniformly tighten the 10 crankshaft bearing cap bolts in several steps in the sequence shown in the illustration.

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      2. Perform the step above again.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    5. Step 2:


      1. Mark the front of each bearing cap bolt head with paint.

      2. Tighten the bearing cap bolts by 60°.

      3. Tighten the bearing cap bolts 60° further.

      4. Check that the paint marks are now at a 120° angle to the front.

    6. Check that the crankshaft turns smoothly.

  7. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD SUB-ASSEMBLY


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

    2. A004PGIE02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Rail
      *4 Oil Ring Expander
      *a Front
      *b Front Mark

      Check the positions of the piston ring ends.

      Note

      Do not align the ring ends.

    3. A004MOBE02

      Using SST (A), install the connecting rod sub-assembly shown in the illustration.

      SST (A)
      PZ4TB-04961-44

      Note


      • Make sure to use SST during the installation.

      • Guide the connecting rod sub-assembly using SST, and make sure that the surface of the fractured connecting rod sub-assembly is not damaged.

    4. A004PYYE01
      Text in Illustration
      *a Front Mark
      A004NPW Front
      A004NAK Press

      Using a hammer handle and SST (B), press a piston and connecting rod sub-assembly into each cylinder with the front mark of the piston facing forward.

      SST (B)
      PZ4TB-04935-82

    5. Remove SST (A) from the connecting rod sub-assembly.

    6. A004MRSE01
      Text in Illustration
      *a Matchmark

      Match the marked connecting rod cap with the connecting rod shown in the illustration.

      Note

      Incorrect installation may result in damage to the connecting rod and crankshaft.

    7. A004P5CE03
      Text in Illustration
      *a Front Mark (Mark F)
      A004NPW Front

      Install the connecting rod cap so that its front mark (Mark F) is facing the correct direction.

      Note


      • Make sure that the front mark of the connecting rod cap is facing forward.


      • Match the numbered connecting rod cap with the connecting rod.

      • Make sure that the surface of the fractured connecting rod does not have foreign matter or become damaged.

      • Do not contact the surface of the fractured connecting rod wearing gloves.

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

      Note


      • Do not reuse the connecting rod cap bolt.

      • Clean the threads of the connecting rod cap bolt.

    9. Step 1:


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

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

    10. Step 2:


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

      2. Tighten the connecting rod cap bolts by 70°.

      3. Check that the paint marks are now at a 70° angle to the front.

    11. Check that the crankshaft turns smoothly.