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. B000IKD

      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. B000HWUE02
      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. B000NL8

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

    3. Coat the piston pin with engine oil.

    4. B000NL5E03
      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. B000L3Z

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

    6. B000I1LE04
      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. B000KV4E07
      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. B000KK3E04
      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. B000MC6E15
      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. B000MPUE08
      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. B000LP7E10
      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. B000LROE03
      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. B000KU0E04
      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. B000HO7E06
      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. B000H8D

      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. B000J0AE05
      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. B000NLPE02

        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. B000L2RE12
        Text in Illustration
        *a Paint Mark
        *b Turn 90°
        B000IB9 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. B000J8HE05

      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. B000MI9E06
      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. B000KK3E04
      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. B000IS0E03
      Text in Illustration
      *a Front Mark
      B000IB9 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. B000K0HE07
      Text in Illustration
      *a Front Mark
      B000IB9 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. B000MMS

        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. B000J8ZE21
      Text in Illustration
      *a Paint Mark
      *b Turn 90°
      B000IB9 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.