CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the piston or piston ring.


PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. A000N0EE02
      Text in Illustration
      *a 46 mm (1.811 in.)
      *b 19 mm (0.748 in.)
      *c 67 mm (2.638 in.)

      Using an E10 "TORX" socket wrench, install the stud bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A000QMPE03
      Text in Illustration
      *a 15709-36010
      *b 15709-36020

      Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzle sub-assemblies with the 4 bolts.

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

      Note

      Install the No. 2 oil nozzle sub-assembly to the same place it was removed from.

      HINT
      Part Number Quantity
      15709-36010 3
      15709-36020 1

  3. INSTALL PISTON

    Tech Tips

    Perform "Inspection After Repair" after replacing the piston.



    1. A000OK5E03
      Text in Illustration
      *1 Piston Pin Hole Snap Ring (Rear)
      *a Protective Tape

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

      Note


      • Only perform this procedure when replacement of the snap ring (rear) is necessary.

      • Tape the screwdriver tip before use.

    2. Gradually heat the piston up to 80 to 90°C (176 to 194°F).

    3. Coat the piston, piston pin and connecting rod sub-assembly with engine oil.

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

    4. A000RMJE03
      Text in Illustration
      *a Front Mark

      Align the front marks of the piston and connecting rod sub-assembly, insert the connecting rod sub-assembly into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the snap ring (rear).

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

      Note

      Do not change the combination of the pistons and piston pins.

  4. INSTALL PISTON PIN HOLE SNAP RING


    1. A000N2EE03
      Text in Illustration
      *1 Piston Pin Hole Snap Ring (Front)
      *a Protective Tape
      *b Front Mark

      Using a screwdriver, install a new piston pin hole snap ring (front) on the other side of the piston pin hole.

      Tech Tips


      • Make sure that the end gap of the piston pin hole snap ring is not aligned with the service hole front mark portion of the piston.

      • Tape the screwdriver tip before use.

  5. INSTALL PISTON WITH CONNECTING ROD


    1. Check the fitting condition between the piston, piston pin and connecting rod sub-assembly.


      1. Move the connecting rod sub-assembly back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, check the piston pin oil clearance Click here.

  6. INSTALL PISTON RING SET

    Tech Tips

    Perform "Inspection After Repair" after replacing the piston or piston ring.



    1. A000OALE15
      Text in Illustration
      *1 Oil Ring Side Rail Upper
      *2 Oil Ring Expander
      *3 Oil Ring Side Rail Lower

      Install the oil ring expander and 2 oil ring side rail by hand.

    2. A000RJRE02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Paint Mark
      *b Code Mark
      B002B6O Upward

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown in the illustration.

      Piston Ring Code Mark
      Item Code Mark Paint Mark
      No. 1 compression ring 1NA Blue
      No. 2 compression ring 2N Green

      Note

      Install the No. 1 compression ring and No. 2 compression ring with the code marks facing upward.

      Tech Tips

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


    3. A000OU2E02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Oil Ring Side Rail Upper
      *5 Oil Ring Side Rail Lower
      *a Front Mark
      B002B6O Engine Front Side

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

      Tech Tips

      The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

  7. INSTALL CRANKSHAFT BEARING


    1. A000QJRE03
      Text in Illustration
      *1 No. 1 Crankshaft Bearing
      *2 No. 2 Crankshaft Bearing
      *3 No. 1 Journal Bearing and No. 3 Journal Bearing
      *4 No. 2 Journal Bearing, No. 4 Journal Bearing and No. 5 Journal Bearing
      *5 No. 1 Journal Bearing and No. 5 Journal Bearing
      *6 No. 2 Journal Bearing, No. 3 Journal Bearing and No. 4 Journal Bearing
      *a Black
      *b Silver

      Clean the main journal and both surfaces of the crankshaft bearing.

    2. Apply engine oil to the crankshaft bearings.

      Note

      Do not apply engine oil to the crankshaft bearing installation area of the main journal or the back side of the crankshaft bearing.

    3. A000O5RE03
      Text in Illustration
      *a Correct
      *b Incorrect
      *c Oil Feed Hole
      *d Oil Groove

      Install the No. 1 crankshaft bearing to the cylinder block assembly as shown in the illustration.

      Note


      • When assembling, note that the No. 1 journal bearing and No. 3 journal bearing have different colors than the No. 2 journal bearing, No. 4 journal bearing and No. 5 journal bearing.

      • Both sides of the oil groove in the cylinder block assembly should be visible through the oil feed holes in the No. 1 crankshaft bearing. The amount visible on each side of the oil feed holes should be equal.

      • Do not allow coolant to come into contact with the No. 1 crankshaft bearing inner surface.

      • If any coolant comes into contact with the No. 1 crankshaft bearing inner surface, replace the No. 1 crankshaft bearing with a new one.

    4. A000Q4WE03
      Text in Illustration
      *1 Crankshaft Bearing Cap
      *2 No. 2 Crankshaft Bearing
      *a Vernier Caliper

      Install the No. 2 crankshaft bearing onto the crankshaft bearing cap.

    5. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the No. 2 crankshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • When assembling, note that the No. 1 journal bearing and No. 5 journal bearing have different colors than the No. 2 journal bearing, No. 3 journal bearing and No. 4 journal bearing.

      • Do not allow coolant to come into contact with the No. 2 crankshaft bearing inner surface.

      • If any coolant comes into contact with the No. 2 crankshaft bearing inner surface, replace the No. 2 crankshaft bearing with a new one.

  8. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. Apply engine oil to the upper crankshaft thrust washers.

    2. A000RZ9E02
      Text in Illustration
      *a Oil Groove
      *b Identification Groove

      Install the 2 upper crankshaft thrust washers onto the No. 3 journal position of the cylinder block assembly with the oil grooves facing outward.

      Note

      Check that the identification groove is in the position shown in the illustration.

  9. INSTALL CRANKSHAFT


    1. Apply engine oil to the No. 1 crankshaft bearings, and install the crankshaft onto the cylinder block assembly.

    2. A000SGYE03
      Text in Illustration
      *1 No. 1 Crankshaft Bearing Cap
      *2 No. 2 Crankshaft Bearing Cap
      *a Front Mark

      Check the front marks and numbers, and install the crankshaft bearing caps onto the cylinder block assembly with the front marks as shown in the illustration.

      Note

      There are 2 types of crankshaft bearing caps. Be sure to install them in their correct positions.

      Tech Tips

      The crankshaft bearing cap set bolts are tightened in 3 progressive steps.

    3. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.

    4. Step 1:


      1. A000NAVE04

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

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    5. Step 2:


      1. Tighten the 10 crankshaft bearing cap set bolts again in the sequence shown in the illustration.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

        If a crankshaft bearing cap set bolt does not meet the specified torque, replace it.

    6. Step 3:


      1. Mark the front of the crankshaft bearing cap set bolts with paint.

      2. Tighten the 10 crankshaft bearing cap set bolts 90° in the same sequence.

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

    7. Check that the crankshaft turns smoothly.

  10. INSTALL CONNECTING ROD BEARING


    1. Clean the connecting rod bearing contact surface of the connecting rod sub-assembly and connecting rod cap, and both surfaces of the connecting rod bearing.

    2. A000SHVE12
      Text in Illustration
      *1 Connecting Rod Cap
      *2 Connecting Rod Bearing
      *a Vernier Caliper

      Install the connecting rod bearing to the connecting rod sub-assembly and connecting rod cap.

    3. Using a vernier caliper, measure the distance between the edges of the connecting rod sub-assembly and connecting rod bearing, and the edges of the connecting rod cap and connecting rod bearing.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


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

      • Do not allow coolant to come into contact with the connecting rod bearing inner surface.

      • If any coolant comes into contact with the connecting rod bearing inner surface, replace the connecting rod bearing with a new one.

  11. INSTALL PISTON WITH CONNECTING ROD


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

      Note

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

    2. A000OU2E02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Oil Ring Side Rail Upper
      *5 Oil Ring Side Rail Lower
      *a Front Mark
      B002B6O Engine Front Side

      Check the position of the piston ring ends again.

      Tech Tips

      The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

    3. A000PC4E03
      Text in Illustration
      *a Front Mark

      Using a hammer handle and piston ring compressor, press a piston with connecting rod sub-assembly into each cylinder with the front mark of the piston facing forward.

      Note

      When inserting the piston with connecting rod sub-assembly into the cylinder block assembly, make sure the connecting rod sub-assembly does not interfere with the No. 2 oil nozzle sub-assembly.

    4. A000QH9E02
      Text in Illustration
      *a Front Mark

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

      Note

      Match the numbered connecting rod cap with the connecting rod sub-assembly.

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

    6. Temporarily install the 2 connecting rod bolts.

    7. Step 1:


      1. Alternately tighten the 2 connecting rod bolts in several steps.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    8. Step 2:


      1. Mark the front of the connecting rod bolts with paint.

      2. Tighten the connecting rod bolts 90°.

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

    9. Check that the crankshaft turns smoothly.