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 CYLINDER BLOCK STRAIGHT SCREW PLUG


    1. B001ZKIE02
      *1 Front
      *2 New Gasket

      Install 2 new gaskets and the 2 straight screw plugs.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01X79T

      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 PIN HOLE SNAP RING


    1. B001Z5LE01
      *1 Cutout Position

      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 pin hole cutout portion of the piston.

  4. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. B001X7DE01

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

    2. Coat the piston pin with engine oil.

    3. B001WX9E01
      *1 Front Mark

      RH:


      1. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

        Tech Tips


        • The piston and pin are a matched set.

        • The piston has 2 front marks.

    4. B001VQKE01
      *1 Front Mark

      LH:


      1. Face the front marks of the piston and connecting rod in opposite directions, and push in the piston pin with your thumb.

        Tech Tips


        • The piston and pin are a matched set.

        • The piston has 1 front mark.

    5. A01X09V

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

  5. INSTALL PISTON PIN HOLE SNAP RING


    1. B001YBME01
      *1 Cutout Position

      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.

  6. INSTALL PISTON RING SET


    1. A01WZA6

      Install the oil ring expander by hand.

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

      Tech Tips

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

      B001VNVE01
      *1 Oil Ring
      *2 Coil Joint
      *3 Oil Ring Expander
      *4 Oil Ring Ends

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

      B001W8ME01
      *1 Code Mark
      *2 No. 1 Compression Ring
      *3 No. 2 Compression Ring

      Tech Tips


      • Install the No. 1 compression ring with no code mark. The compression ring can be installed with either side facing upward.

      • Install the No. 2 compression ring with the code mark shown in the table below facing upward.

      Standard Code Mark
      Item

      Code Mark

      (w/ EGR System)

      Code Mark

      (w/o EGR System)
      No. 1 compression ring No mark No mark
      No. 2 compression ring T2 2T

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

      B001WIJE01

  7. INSTALL CONNECTING ROD BEARING


    1. B001VVME02
      *1 Claw

      Align the bearing claw with the claw groove of the connecting rod cap.

      Note


      • Clean the contact surface of the bearing and connecting rod cap.

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

    2. Align the bearing claw with the claw groove of the connecting rod.

      Note


      • Clean the contact surface of the bearing and connecting rod.

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

  8. INSTALL CRANKSHAFT BEARING

    Note

    Be sure to install the selected bearing.

    Tech Tips

    Main bearings come in widths of 20.5 mm (0.807 in.) and 22.5 mm (0.886 in.).

    B001ZTRE01
    *1 No. 1 and 5 Journal Bearings
    *2 No. 2, 3 and 5 Journal Bearings
    *3 22.5 mm
    *4 20.5 mm
    Bearing Width
    Item Standard Width
    No. 1 and 5 journal bearings 22.5 mm (0.886 in.)
    No. 2, 3 and 4 journal bearings 20.5 mm (0.807 in.)

    1. Clean each main journal and bearing.

    2. A01WZ4H

      Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper crankshaft bearings.

      Note


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

      • Do not apply engine oil to the bearing and its 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.

    3. A01X8WM

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

      Note


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

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

      Tech Tips

      The number marked on each bearing cap indicates the installation position.

  9. INSTALL CRANKSHAFT

    Note

    Clean the contact surface of each main journal and crank pin.


    1. A01X342

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

    2. B001VXSE04
      *1 Oil Groove

      Push the crankshaft toward the rear thrust direction to create clearance, and install a thrust washer to the No. 3 journal position with the oil groove facing the front of the engine.

    3. Push the crankshaft toward the forward thrust direction to create clearance, and install a thrust washer to the No. 3 journal position with the oil groove facing the rear of the engine.

    4. B001Z82E01
      *1 Front

      Examine the front marks and numbers and install the bearing caps to the cylinder block.

    5. Apply a light coat of engine oil to the threads of the crankshaft bearing cap bolts.

    6. Temporarily install the crankshaft bearing cap bolts labeled A or the bolts labeled B.

      B001WUYE01

      Tech Tips

      In place of the cylinder block stiffening plates, install 8 mm (0.315 in.) thick spacers to the crankshaft bearing cap bolts.

      Standard Length
      Item Diameter Length
      A 11 mm (0.433 in.) 106 mm (4.17 in.)
      B 10 mm (0.394 in.) 90.5 mm (3.56 in.)

    7. Uniformly tighten the 2 crankshaft bearing cap bolts for each bearing cap in several passes to ensure a proper fit.

      Note

      Do not tap the bearing cap with a plastic-faced hammer.

    8. Remove the crankshaft bearing cap bolts and spacers.

    9. B001Z5AE02
      *1 Front Mark

      Set the 2 cylinder block stiffening plates on the cylinder block.

      Tech Tips

      Make sure the arrows on the stiffening plates face the engine front.

    10. B001Y4KE02

      Step 1:

      Tech Tips


      • The crankshaft bearing cap bolts are tightened in 4 progressive steps.

      • If any crankshaft bearing cap bolt is broken or deformed, replace it.


      1. Apply a light coat of engine oil to the threads and under the heads of the 20 crankshaft bearing cap bolts A and B.

      2. Install the 20 crankshaft bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.

        Torque:
        for bolt A
        35 N*m  { 357 kgf*cm, 26 ft.*lbf }
        for bolt B
        60 N*m  { 612 kgf*cm, 44 ft.*lbf }
    11. B001Y4BE02

      Step 2:


      1. Mark the front side of the crankshaft bearing cap bolts A and B with paint.

      2. Tighten the crankshaft bearing cap bolts A and B 90° in the sequence shown in the illustration.

    12. B001W7RE02

      Step 3:


      1. Tighten the crankshaft bearing cap bolts A another 90° in the sequence shown in the illustration.

    13. B00206NE05
      *1 Front
      *2 Painted Mark

      Check that the painted marks of bolt A are now at a 180° angle to the front.

    14. B001XOGE06
      *1 Painted Mark
      *2 Front

      Check that the painted marks of bolt B are now at a 90° angle to the front.

    15. Check that the crankshaft turns smoothly.

    16. B001ZXUE02

      Step 4:


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

        Torque:
        56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      2. Check that the crankshaft turns smoothly.

  10. INSPECT CRANKSHAFT THRUST CLEARANCE

    Click here

  11. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

      B001WIJE01

    2. Check the positions of the piston ring ends.

    3. 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.

      B001WE6E01
      *1 Front Mark
      *2 Front
    4. B001XLUE02
      *1 Front
      *2 Rear
      *3 Protrusion

      Install the connecting rod cap so that its protrusion is facing the correct direction.

      Note

      Match the numbered connecting rod cap with the connecting rod.

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

    6. Step 1:


      1. A01X48X

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

        Torque:
        35 N*m  { 357 kgf*cm, 26 ft.*lbf }

        Tech Tips


        • The connecting rod cap bolts are tightened in 2 progressive steps.

        • If any connecting rod cap bolt is broken or deformed, replace it.

    7. Step 2:


      1. B001ZU3E09
        *1 Front
        *2 Painted Mark

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

      2. Tighten the cap bolts 90°.

    8. B001XOGE06
      *1 Painted Mark
      *2 Front

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

    9. Check that the crankshaft turns smoothly.

  12. INSPECT CONNECTING ROD THRUST CLEARANCE

    Click here