CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. Using an E8 and E10 "TORX" socket wrench, install the stud bolts.

      A000XNCE04
      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. A000UP6

      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. A000XY0E02
      *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. Coat the piston pin and connecting rod with engine oil.

    3. A000V4PE05
      *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.

    4. A000UQ6

      Move the connecting rod back and forth on the piston pin. Check the fitting condition.

    5. Rotate the piston back and forth on the piston pin. Check the fitting condition.

    6. A000XY0E02
      *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 service hole of the piston.

  4. INSTALL PISTON RING SET


    1. Install the oil ring expander by hand.

      A000TU5E02
      *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 in the illustration.

      Tech Tips

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

    3. A000W37E08
      *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. A000VKRE02
      *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. Install the upper bearing.

      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 crankshaft bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.


      1. A000YUPE01
        *1 CORRECT
        *2 INCORRECT

        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. A000YIYE02
      *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. A000Z7G

      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 crankshaft bearing cap with the oil grooves facing outward.

  7. INSTALL CRANKSHAFT


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

    2. A000VFRE01
      *1 Number Mark

      Confirm the front marks and numbers of the crankshaft bearing caps, and install the crankshaft bearing caps on the cylinder block.

      Tech Tips

      A number is marked on each crankshaft 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 crankshaft bearing cap bolts to the inside positions.

    5. A000WTHE01
      *1 91 mm
      *2 Less than 6 mm

      Push the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block is less than 6 mm (0.236 in.).

      Bolt length
      91 mm (3.58 in.)
    6. A000TMW

      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 crankshaft bearing cap bolts.

    8. A000ZW5E01
      *1 79.5 mm

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

      Bolt length
      79.5 mm (3.13 in.)

      Tech Tips

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

    9. Step 1:


      1. A000V0KE08

        Uniformly tighten the 20 crankshaft 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 a crankshaft bearing cap bolt does not meet the specified torque, replace it.

    10. Step 2:


      1. A000T96E21
        *1 Painted Mark
        *2 Front

        Mark the front of the bearing cap bolts with paint.

      2. Tighten the bearing cap bolts 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. A000UONE07

      Install and uniformly tighten the 10 crankshaft 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. A000X0DE01
      *1 Vernier Caliper

      Install the connecting rod bearings to the connecting rods and bearing caps.

    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 0.0276 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. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

    2. A000ZD3E02

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

      Note

      Do not align the ring ends.

    3. A000X3AE03
      *1 for Bank 1:
      *2 Front Mark
      *3 for Bank 2:

      Using a hammer handle and piston ring compressor, press a piston and connecting rod into each 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. A000XW9E04
      *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 rod cap bolts.

      Tech Tips

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

    7. Step 1:


      1. A000XKQ

        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. A000YW5E06
      *1 Painted Mark
      *2 Front

      Step 2:


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

      2. Tighten the cap bolts 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.