CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


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

      Torque:
      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 }
      B001ZYZE02
      Text in Illustration
      *a Upper Side *b Lower Side

  2. 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.

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

  3. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. B001ZG6E03
      Text in Illustration
      *1 Service Cutout

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

      Tech Tips

      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. B001WO8E01
      Text in Illustration
      *A for Bank 1
      *B for Bank 2
      *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.

      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.

      Tech Tips

      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. B001ZG6E03
      Text in Illustration
      *1 Service Cutout

      Using a small 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 cutout of the piston.

  4. INSTALL PISTON RING SET


    1. B001WZEE02
      Text in Illustration
      *1 Upper Side Rail
      *2 Oil Ring Expander
      *3 Lower Side Rail

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

    2. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.

      B001VWJE05
      Text in Illustration
      *1 No. 1 Compression Ring *2 No. 2 Compression Ring
      *a Type A *b Type B
      *c Piston Ring Expander *d Paint Mark
      *e Upward - -

      Tech Tips

      Type A and type B can be distinguished by the color of the paint marks or the cross-section shape of the No. 2 compression ring.

      Item Paint Mark
      Type A No. 1 compression ring Blue
      No. 2 compression ring Orange
      Type B No. 1 compression ring Yellow
      No. 2 compression ring Green
    3. B001X95E02
      Text in Illustration
      *1 Front Mark
      *2 Upper Side Rail
      *3 Lower Side Rail
      *4 No. 1 Compression Ring
      *5 No. 2 Compression Ring

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

  5. INSTALL CRANKSHAFT BEARING

    B001YYAE33
    Text in Illustration
    *1 No. 1 and No. 5 Journal Bearings
    *2 No. 2, No. 3 and No. 4 Journal Bearings

    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.


    1. Clean each main journal and bearing.

    2. Install the upper bearing.


      1. B001Z1TE02
        Text in Illustration
        *1 Oil Groove
        *2 Oil Feed Hole
        *a CORRECT
        *b INCORRECT

        Install the upper bearing to the cylinder block.

        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. B001ZW5E03
        Text in Illustration
        *1 Vernier Caliper

        Install the lower bearings to the crankshaft bearing caps.

      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.

  6. INSTALL CRANKSHAFT THRUST WASHER SET


    1. B001YS6E03
      Text in Illustration
      *1 Oil Groove

      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. B001XIJE01
      Text in Illustration
      *1 Number Mark

      Apply new 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 to 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 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. B001YI0E02
      Text in Illustration
      *a 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 (0.236 in.) and partially tighten the 2 inner bearing cap bolts.

      Bolt length
      91 mm (3.58 in.)
    6. B001XYA

      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. B001VRHE01
      *1 79.5 mm

      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.

      Tech Tips

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


      1. B001XRWE03

        Step 1:

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

        Torque:
        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. B001YC8E03

      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.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

    12. Check that the crankshaft turns smoothly.

  8. INSTALL CONNECTING ROD BEARING


    1. B001YWKE01
      Text in Illustration
      *1 Vernier Caliper
      *2 Connecting Rod Cap
      *3 Connecting Rod Bearing

      Install the bearing to the connecting rod cap.

      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. B001WWVE01
      Text in Illustration
      *1 Vernier Caliper
      *2 Connecting Rod
      *3 Connecting Rod Bearing

      Install the bearing to the connecting rod.

      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.)

  9. INSPECT CRANKSHAFT THRUST CLEARANCE

    Click here

  10. INSTALL PISTON AND CONNECTING ROD


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

    2. B001X95E02
      Text in Illustration
      *1 Front Mark
      *2 Upper Side Rail
      *3 Lower Side Rail
      *4 No. 1 Compression Ring
      *5 No. 2 Compression Ring

      Check the positions of the piston ring ends.

      Note

      Do not align the ring ends.

      Tech Tips

      The expander ends can be placed anywhere.

    3. B001Z5QE02
      Text in Illustration
      *A for Bank 1
      *B for Bank 2
      *1 Front Mark

      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.

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


      1. B001X8ME03
        Text in Illustration
        *A for Bank 1
        *B for Bank 2
        *1 Front Mark
        B001XPG Front

        Match the numbered connecting rod cap with the connecting rod.

      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.

      Tech Tips

      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. B001VZF

        Step 1:

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

        Torque:
        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.