CYLINDER BLOCK REASSEMBLY

Tech Tips

Perform "Inspection After Repair" after replacing the piston and piston ring Click here.


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01I1YK

      Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL PISTON


    1. A01HZL3E02
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

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

    2. A01I07N

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

    3. Coat the piston pin with engine oil.

    4. A01I16BE03
      Text in Illustration
      *a Front Mark

      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.

    5. A01HYFP

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

    6. A01I08GE04
      Text in Illustration
      *1 Service Hole

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

      Tech Tips


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

      • Perform "Inspection After Repair" after replacing the piston Click here.

  3. INSTALL PISTON RING SET


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

    2. A01I1SPE07
      Text in Illustration
      *1 Piston Ring Expander
      *2 Upper Side Rail
      *3 Oil Ring Expander
      *4 Lower Side Rail
      *5 Oil Ring
      *6 No. 1 Ring
      *7 No. 2 Ring

      Using a piston ring expander, install the compression ring as shown in the illustration.

    3. A01I1MIE04
      Text in Illustration
      *1 Lower Side Rail
      *2 No. 2 Ring
      *3 Oil Ring Expander
      *4 No. 1 Ring
      *5 Upper Side Rail
      *a Front Mark

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

      Note

      Do not align the ring ends.

      Tech Tips

      Perform "Inspection After Repair" after replacing the piston ring Click here.

  4. INSTALL CRANKSHAFT BEARING


    1. A01HZOLE15
      Text in Illustration
      *1 No. 1 and No. 4 Journal Bearing
      *2 No. 2 and No. 3 Journal Bearing

      Clean the main journal and both surfaces of the bearings.

      Note

      Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

    2. A01HZKFE08
      Text in Illustration
      *1 Upper Bearing
      *a CORRECT
      *b INCORRECT

      Install the upper crankshaft bearing.


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

        Note


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

    3. A01HZ9VE10
      Text in Illustration
      *1 Vernier Caliper
      *a Mark 1, 2, 3, 4 or 5

      Install the lower crankshaft bearing.


      1. Install the lower crankshaft bearings to the crankshaft bearing caps.

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

        Dimension (A - B)
        0.7 mm (0.0276 in.) or less

        Note

        Do not apply engine oil to the crankshaft bearings and the contact surfaces.

  5. INSTALL CRANKSHAFT THRUST WASHER SET


    1. Apply engine oil to the crankshaft thrust washer.

    2. A01HZBJE03
      Text in Illustration
      *1 Oil Grooves

      Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

  6. INSTALL CRANKSHAFT


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

    2. A01HXUWE04
      Text in Illustration
      *1 Projection
      *a Number Mark

      Confirm the projections and numbers on the main bearing caps and install the crankshaft 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 to the threads and under the heads of the crankshaft bearing cap bolts.

    4. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

    5. A01I0B1E06
      Text in Illustration
      *a Less than 6 mm
      *b Bolt Length 100 to 102 mm

      Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide.

      Bolt length
      100 to 102 mm (3.94 to 4.02 in.)
    6. A01I1ID

      Using a plastic 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 8 crankshaft bearing cap bolts.

    8. A01HYVIE05
      Text in Illustration
      *a Bolt Length

      Install the 8 crankshaft bearing cap bolts to the outside positions.

      Bolt length
      105.5 to 107.5 mm (4.15 to 4.23 in.)

    9. Install the crankshaft bearing cap bolts.

      Tech Tips

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

    10. Step 1


      1. A01HYZNE02

        Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

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

        If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it.

    11. Step 2


      1. A01HXZZE12
        Text in Illustration
        *a Paint Mark
        *b Turn 90°
        A01HZQC Engine Front

        Mark the front of the bearing cap bolts with paint.

      2. Retighten the bearing cap bolts 90° in the sequence shown in the illustration.

      3. Check that the painted mark is now at a 90° angle to the front of the engine.

    12. A01I0Y0E05

      Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

      Torque:
      52 N*m  { 525 kgf*cm, 38 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 45 mm (1.77 in.)
      Except bolt A 30 mm (1.18 in.)

    13. Check that the crankshaft turns smoothly.

    14. Check the crankshaft thrust clearance Click here.

  7. INSTALL CONNECTING ROD BEARING


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

    2. A01HY1OE06
      Text in Illustration
      *1 Vernier Caliper

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

      Dimension (A - B)
      0.7 mm (0.0276 in.) or less

      Note

      Do not apply engine oil to the bearings and the contact surfaces.

  8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A01I1MIE04
      Text in Illustration
      *1 Lower Side Rail
      *2 No. 2 Ring
      *3 Oil Ring Expander
      *4 No. 1 Ring
      *5 Upper Side Rail
      *a Front Mark

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

      Note

      Do not align the ring ends.

    3. A01HZ2UE03
      Text in Illustration
      *a Front Mark
      A01HZQC Engine Front

      Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

      Note

      Match the numbered connecting rod cap with the connecting rod.

    4. A01HZH9E07
      Text in Illustration
      *a Front Mark
      A01HZQC Engine Front

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

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

    6. Install the connecting rod cap bolts.

      Tech Tips

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

    7. Step 1


      1. A01HXTU

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

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    8. A01HZLAE21
      Text in Illustration
      *a Paint Mark
      *b Turn 90°
      A01HZQC Engine Front

      Step 2


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

      2. Retighten the cap bolts 90° as shown in the illustration.

      3. Check that the painted mark is now at a 90° angle to the front.

    9. Confirm that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance Click here.