CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Note

Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block sub-assembly, connecting rod sub-assembly and other parts.

PROCEDURE


  1. INSTALL CYLINDER BLOCK STRAIGHT SCREW PLUG


    1. Install 2 new gaskets and the 2 cylinder block straight screw plugs.

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

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

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

  3. INSTALL PISTON PIN HOLE SNAP RING


    1. A01WSMF

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

      Text in Illustration
      B0018FC Cutout Position

      Tech Tips

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

  4. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. Heat the piston to approximately 80°C (176°F).

    2. Coat the piston pin with engine oil.

    3. A01WW7VE02
      Text in Illustration
      *a 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 piston pin are a matched set.

        • The piston has 2 front marks.

    4. A01WWTQE02
      Text in Illustration
      *a 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 piston pin are a matched set.

        • The piston has 1 front mark.

    5. 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. A01WUMS

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

      Text in Illustration
      B0018FC Cutout Position

      Tech Tips

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

  6. INSTALL PISTON RING SET


    1. Install the oil ring expander by hand.

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

      A01WRE8E03
      Text in Illustration
      *1 Oil Ring Expander
      *2 Oil Ring
      *a Coil Joint
      *b Oil Ring Ends

      Tech Tips

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

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

      A01WTYJE03
      Text in Illustration
      *1 No. 1 Compression Ring *2 No. 2 Compression Ring
      *a Code Mark - -

      Tech Tips


      • Install the No. 1 compression ring with no code mark. The No. 1 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. A01WWSWE02
      Text in Illustration
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *4 Oil Ring Expander
      *a Front Mark

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

  7. INSTALL CONNECTING ROD BEARING


    1. A01WQPRE02
      Text in Illustration
      *a Claw

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

      Note


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

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

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

      Note


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

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

  8. INSTALL CRANKSHAFT BEARING

    Note

    Be sure to install the selected crankshaft bearing.

    Tech Tips

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

    A01WR1BE02
    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.)
    Text in Illustration
    *a No. 1 and No. 5 Journal Bearings
    *b No. 2, 3 and No. 5 Journal Bearings
    *c 22.5 mm (0.886 in.)
    *d 20.5 mm (0.807 in.)

    1. Clean each main journal and crankshaft bearing.

    2. A01WTZU

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

      Note


      • Clean the contact surface of the upper crankshaft bearing and cylinder block sub-assembly.

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

      • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the upper crankshaft bearing. The amount visible on each side of the holes should be equal.

    3. A01WQK0

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

      Note


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

      • Do not apply engine oil to the lower crankshaft 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. Apply new engine oil to the upper crankshaft bearing and install the crankshaft to the cylinder block sub-assembly.

    2. A01WS3YE05
      Text in Illustration
      *a Oil Groove

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

    4. A01WTDVE03
      Text in Illustration
      *a Front

      Examine the front marks and numbers and install the crankshaft bearing caps to the cylinder block sub-assembly.

    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.

      A01WSC1E03
      Text in Illustration
      *a 8 mm (0.315 in.)
      *b Spacer
      *c 106 mm (4.17 in.)
      *d 90.5 mm (3.56 in.)
      *e 11 mm (0.433 in.)
      *f 10 mm (0.394 in.)

      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 crankshaft bearing cap in several passes to ensure a proper fit.

      Note

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

    8. Remove the crankshaft bearing cap bolts and spacers.

    9. A01WUOAE02
      Text in Illustration
      *a Front Mark

      Set the 2 cylinder block stiffening plates on the cylinder block sub-assembly.

      Tech Tips

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

    10. A01WPJYE02

      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. A01WURIE02
      Text in Illustration
      *a Painted Mark
      *b Front

      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. A01WQD3E02
      Text in Illustration
      *a Painted Mark
      *b Front

      Step 3:


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

    13. A01WSMAE06
      Text in Illustration
      *a Painted Mark
      *b Front

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

    14. A01WT68E07
      Text in Illustration
      *a Painted Mark
      *b Front

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

    15. Check that the crankshaft turns smoothly.

    16. A01WW5OE02

      Step 4:


      1. Using several steps, install the 10 crankshaft bearing cap set 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. A01WWSWE02
      Text in Illustration
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *4 Oil Ring Expander
      *a Front Mark

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

    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.

      A01WQO7E02
      Text in Illustration
      *a RH
      *b LH
      *c Front Mark
      *d Front
    4. A01WWWWE01
      Text in Illustration
      *a RH
      *b LH
      *c Front
      *d Rear
      *e 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. A01WRS7

        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. A01WVDCE14
        Text in Illustration
        *a Painted Mark
        *b Front

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

      2. Tighten the cap bolts 90°.

    8. A01WT68E08
      Text in Illustration
      *a Painted Mark
      *b 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