CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


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

      A001FOWE07
      Torque:
      for stud bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for stud bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A001D6M

      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 PISTON WITH PIN SUB-ASSEMBLY


    1. A001EGYE02
      *1 Service Hole

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

      Tech Tips

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

    2. A001CEL

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

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

    4. A001BXOE01
      *1 for Bank 1:
      *2 Front Mark
      *3 for Bank 2:

      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 snap ring.

      Front mark
      Item Front Mark
      Bank 1 Piston 1
      Bank 2 Piston 2

      Note

      For bank 1, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For bank 2, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides.

      Tech Tips

      The piston and pin are a matched set.

    5. A001C8J

      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. A001EGYE02
      *1 Service Hole

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

      Tech Tips

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

  4. INSTALL PISTON RING SET


    1. Install the oil ring expander by hand.

      A001E1ZE01
      *1 Coil Joint
      *2 Oil Ring Expander
      *3 Oil Ring Ends
      *4 Oil Ring

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

    3. A001CAME08
      *1 Code Mark
      *2 No. 1 Ring
      *3 No. 2 Ring

      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.

  5. INSTALL CRANKSHAFT BEARING


    1. A001EY1E07
      *1 No. 1 and No. 5 Journal Bearings:
      *2 No. 2, No, 3 and No. 4 Journal Bearings:
      *3 22.5 mm
      *4 21 mm

      Clean the main journal and both surfaces of the bearing.

    2. A00197WE01
      *1 CORRECT
      *2 INCORRECT

      Install the upper bearing.

      Note

      Main bearings come in widths of 21 mm (0.8268 in.) and 22.5 mm (0.8858 in.). Install the 22.5 mm (0.8858 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.8268 in.) bearings in the No. 2, No. 3 and No. 4 positions.


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

        Note


        • Do not apply engine oil to the bearings and the contact surface.

        • 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. A001D4WE02
      *1 Mark 1, 2, 3, 4 or 5

      Install the lower bearing.


      1. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

        Note


        • Do not apply engine oil to the bearings and the contact surface.

        • 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.

  6. INSTALL CRANKSHAFT THRUST WASHER SET


    1. A001FQ2

      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.

  7. INSTALL CRANKSHAFT


    1. A001CSBE01
      *1 Number Mark

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

    2. Confirm the front marks and numbers of the main bearing caps, and install the bearing caps on 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 on 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. A001BMWE01
      *1 91 mm
      *2 Less Than 6 mm

      Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

      Bolt length
      91 mm (3.583 in.)
    6. A001C9O

      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. A0018XZE01
      *1 79.5 mm

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

      Bolt length
      79.5 mm (3.130 in.)

      Tech Tips

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

    9. Step 1:


      1. A001EMRE06

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

        Torque:
        for Inside position
        61 N*m  { 622 kgf*cm, 45 ft.*lbf }
        for Outside position
        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.

    10. Step 2:


      1. A00197RE21
        *1 Painted Mark
        *2 Front

        Mark the front of the bearing cap bolts 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. A001C9NE03

      Install and uniformly tighten the 10 main bearing cap bolts and 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.

  8. INSTALL CONNECTING ROD BEARING


    1. A001B6SE01
      *1 Vernier Caliper

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

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

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.028 in.)

      Note


      • Do not apply engine oil to the bearings and the contact surface.

      • 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.

  9. INSTALL PISTON AND CONNECTING ROD


    1. A001CSIE01

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

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

      Note

      Do not align the ring ends.

    3. A001AUME01
      *1 for Bank 1:
      *2 Front Mark
      *3 for Bank 2:

      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
      Bank 2 2
    4. A001BG4E05
      *1 Front
      *2 Front Mark

      Check that the front mark of the connecting rod cap is facing forward.

      Front Mark
      Item Front 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 cap bolts.

      Tech Tips

      The connecting cap bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. A001AZU

        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. A001E7CE01
      *1 Painted Mark
      *2 Front

      Step 2:


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

      2. Tighten the 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.

    9. Check that the crankshaft turns smoothly.