CYLINDER BLOCK REASSEMBLY

Tech Tips

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


  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.

      B000NBCE03
      Text in Illustration
      *a RH Side: *b LH Side:
      Torque:
      for stud bolt A
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      for stud bolt B
      8.5 N*m  { 87 kgf*cm, 75 ft.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. B000LJL

      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 NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B000JJ7

      Using a 5 mm hexagon wrench, install the 2 oil nozzles with the 2 bolts.

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

  4. INSTALL PISTON


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

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

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

    4. B000JBVE04
      Text in Illustration
      *a Front Mark

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

      Tech Tips

      The piston and pin are a matched set.

    5. B000MHQE02
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

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

    6. B000J74

      Check the fitting condition between the piston and piston pin.


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

        If abnormal movement is felt, replace the piston and pin as a set.

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

        If abnormal movement is felt, replace the piston and pin as a set.

        Tech Tips

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

  5. INSTALL PISTON RING SET

    Note

    During installation, use a type A piston ring set for the type A piston, and a type B piston ring set for the type B piston.

    B000M6TE01
    Text in Illustration
    *A Type A *B Type B
    *1 Piston *2 Oil Ring

    1. Type A:


      1. B000NOSE04
        Text in Illustration
        *1 Oil Ring
        *2 Oil Ring Expander
        *3 Coil Joint
        *4 Oil Ring End

        Install the oil ring expander and oil ring by hand.

        Tech Tips

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

    2. Type B:


      1. B000JPSE01
        Text in Illustration
        *1 Upper Oil Ring Side Rail
        *2 Oil Ring Expander
        *3 Lower Oil Ring Side Rail

        Install the oil ring expander, upper oil ring side rail and lower oil ring side rail by hand.

    3. B000N93E01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Piston Ring Expander
      *b Code Mark (1N, 1NA or N1)
      *c Code Mark (2N or N2)
      *d Paint Mark
      B000K70 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 Mark
      Item Code Mark
      No. 1 Compression Ring 1N, 1NA or N1
      No. 2 Compression Ring 2N or N2

      Note

      Install the compression ring with the code mark facing upward.

      Tech Tips

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

  6. INSTALL CRANKSHAFT PULLEY KEY


    1. Install the 2 crankshaft pulley keys to the crankshaft.

  7. INSTALL CRANKSHAFT BEARING


    1. B000J07E03
      Text in Illustration
      *a CORRECT
      *b INCORRECT

      Clean the main journal and both surfaces of the bearing.

    2. Install the upper bearing to the cylinder block as shown in the illustration.

      Note


      • Do not apply engine oil to the bearings or their 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.

      • 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. B000H2ZE02
      Text in Illustration
      *1 Vernier Caliper

      Install the lower bearing onto the bearing cap.

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

      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 bearings and the contact surfaces.

      • 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.

  8. INSTALL CRANKSHAFT THRUST WASHER


    1. B000KGRE02
      Text in Illustration
      *1 Oil Groove

      Apply engine oil to the thrust washers.

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

  9. INSTALL CRANKSHAFT


    1. B000LKNE04
      Text in Illustration
      *a Front Mark

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

    2. Examine the front marks and numbers, and install the bearing caps onto the cylinder block with the front marks as shown in the illustration.

      Tech Tips

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

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

    4. Step 1:


      1. B000HHXE03

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

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

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

    6. Step 3:


      1. B000IHTE05
        Text in Illustration
        *a Paint Mark
        B000IB9 Engine Front

        Mark the front of the bearing cap bolts with paint.

      2. Tighten the 10 bearing cap 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. B000H59E02
      Text in Illustration
      *1 Vernier Caliper

      Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings.

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

    3. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing 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 bearings and the contact surfaces.

      • 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.

  11. INSTALL PISTON WITH CONNECTING ROD

    Tech Tips

    Type A and type B can be distinguished by the mark on the piston and the shape of the oil ring.

    B000M6TE01
    Text in Illustration
    *A Type A *B Type B
    *1 Piston *2 Oil Ring

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

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

      B000JG7E02
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Compression Ring *2 No. 2 Compression Ring
      *3 Oil Ring *4 Oil Ring Expander
      *5 Oil Ring Expander (Coil Joint) *6 Upper Oil Ring Side Rail
      *7 Lower Oil Ring Side Rail - -

      Tech Tips

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

    3. B000MR6E04
      Text in Illustration
      *a Front Mark

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

      Note

      When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod.

      Tech Tips

      The front mark is "2L" or "2S" printed in raised letters.

    4. B000L8DE06
      Text in Illustration
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing in the correct direction.

      Note

      Match the numbered connecting rod cap with the connecting rod.

    5. B000GYM

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

    6. Temporarily install the connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:


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

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. B000J8ZE25
      Text in Illustration
      *a Paint Mark
      B000IB9 Engine Front

      Step 2:


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

      2. Tighten the bolts 90° as shown in the illustration.

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

    9. Check that the crankshaft turns smoothly.