CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using a 5 mm hexagon wrench, install the 3 No. 1 oil nozzle sub-assemblies with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
  2. INSTALL CONNECTING ROD SMALL END BUSH


    1. B003TNYC01
      *1 Oil Hole

      Align the oil holes of a new connecting rod small end bush and the connecting rod sub-assembly.

    2. B003WZTN10

      Using SST and a press, press in the connecting rod small end bush.

      SST
      09222-30010
    3. B003TPC

      Using a pin hole grinder, hone the bush to obtain the specified clearance between the connecting rod small end bush and piston pin.

      Standard oil clearance
      -0.002 to 0.004 mm (-0.00008 to 0.00016 in.)
    4. Check that the piston pin fits at normal room temperature.

    5. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

  3. INSTALL PISTON SUB-ASSEMBLY WITH PIN


    1. B003WQGC01
      *1 Cutout Portion

      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 piston pin hole snap ring is not aligned with the pin hole cutout portion of the piston.

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

      CAUTION:

      Be sure to wear protective gloves

    3. Coat the piston pin with engine oil.

    4. B003UQKC01
      *1 Front Mark
      *a for Bank 1
      *b for Bank 2

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

    6. B003WQGC01
      *1 Cutout Portion

      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 piston pin hole snap ring is not aligned with the pin hole cutout portion of the piston.

    7. Check that the piston moves smoothly.

  4. INSTALL PISTON RING SET


    1. Install the oil ring expander by hand.

    2. Using a piston ring expander, install the oil ring as shown in the illustration.

      B003T8VC02
      *1 Oil Ring *2 Oil Ring Expander
      *3 Front Mark *4 Oil Ring End
      *5 Oil Ring Expander End - -
      *a for Bank 1 *b for Bank 2
      B003WAF Engine Front - -
    3. B003WFYC01
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Code Mark

      Using a piston ring expander, install the No. 2 compression ring and No. 1 compression ring so that the painted 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.

    4. B003W3IC03
      *1 Front Mark
      *2 No. 1 Compression Ring End
      *3 No. 2 Compression Ring End
      *a for Bank 1
      *b for Bank 2
      B003WAF Engine Front

      Position the No. 1 compression ring and No. 2 compression ring so that the ring ends are as shown in the illustration.

      Note

      Do not align the ring ends.

  5. INSTALL CRANKSHAFT BEARING


    1. B003T6IC02
      *1 No. 1 and No. 4 Journal Bearing
      *2 No. 2 and No. 3 Journal Bearing
      *a 21 mm (0.827 in.)
      *b 18 mm (0.709 in.)

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

      Note

      Crankshaft 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 crankshaft bearing cap. Install the 18.0 mm (0.709 in.) crankshaft bearings in the No. 2 and No. 3 positions.

    2. B003X34C03
      *1 Oil Groove
      *2 Oil Feed Hole
      *a CORRECT
      *b INCORRECT

      Install the upper crankshaft bearing.


      1. Install the upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

        Note


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

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

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

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

    3. B003X2MC02
      *1 Journal Number
      *2 Vernier Caliper

      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.

        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 crankshaft bearings and the contact surfaces.

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

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

  6. INSTALL CRANKSHAFT THRUST WASHER SET


    1. Apply engine oil to the crankshaft thrust washer set.

    2. B003X79C02
      *1 Oil Groove

      Install the crankshaft thrust washer set to the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

      Note

      Be sure not to install the crankshaft thrust washer set the wrong way around.

  7. INSTALL CRANKSHAFT


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

    2. Apply engine oil to the lower crankshaft bearing.

    3. B003WNQC03
      *1 Projection
      *2 Number Mark

      Confirm the projections and numbers on the crankshaft bearing caps and install the crankshaft bearing caps on the cylinder block sub-assembly.

      Tech Tips

      A number is marked on each crankshaft bearing cap to indicate the installation position.

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

    5. Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.

      Note

      Confirm the crankshaft bearing cap set bolt length before installing.

      Bolt Length
      100 to 102 mm (3.94 to 4.02 in.)
    6. B003T7EC04
      *a Less than 6 mm (0.236 in.)
      *b Bolt Length

      Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block sub-assembly is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap set bolts as a guide.

    7. B003U8H

      Using a plastic-faced hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

    8. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap set bolts.

    9. B003WOAC02
      *a Bolt Length

      Install the 8 crankshaft bearing cap set bolts to the outside positions.

      Note

      Confirm the crankshaft bearing cap set bolt length before installing.

      Bolt Length
      Item Specified Condition
      Bolt A 100 to 102 mm (3.94 to 4.02 in.)
      Except bolt A 105.5 to 107.5 mm (4.15 to 4.23 in.)
    10. Tighten the crankshaft bearing cap set bolts.

      Tech Tips

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

    11. Step 1


      1. B003W7GN15

        Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps and in the sequence shown in the illustration.

        Torque:
        61 N*m  { 622 kgf*cm, 45 ft.*lbf }

        Note

        Check that the crankshaft turns smoothly during the procedure.

        If any of the crankshaft bearing cap set bolts does not meet the torque specified, replace it.

    12. Step 2


      1. B003V5LC01
        *1 Paint Mark
        *a 90°
        B003WAF Engine Front

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

      2. Tighten the crankshaft bearing cap set bolts another 90°.

      3. Check that the painted marks are now at a 90° angle to the front of the engine.

    13. B003TP0N02

      Install 8 new seal washers and uniformly tighten the 8 bolts in several steps and in the sequence shown in the illustration.

      Torque:
      25.7 N*m  { 262 kgf*cm, 19 ft.*lbf }

      Note


      • Check that the crankshaft turns smoothly during the procedure.

      • Confirm the crankshaft bearing cap set bolt length before installing.

      Bolt Length
      Item Specified Condition
      Bolt A 45 mm (1.77 in.)
      Except bolt A 30 mm (1.18 in.)
    14. Check that the crankshaft turns smoothly.

    15. Check the crankshaft thrust clearance.

      Click here

  8. INSTALL CONNECTING ROD BEARING


    1. Clean the connecting rod, connecting rod cap and connecting rod bearing.

    2. Install the connecting rod bearings to the connecting rod and connecting rod cap.

    3. B003USZC01
      *1 Vernier Caliper

      Using a vernier caliper, measure the distance between each connecting rod bearing edge and the connecting rod edges, and the connecting rod cap edges respectively.

      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 connecting rod 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.

  9. 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. B003WXAC05
      *1 Front Mark
      *2 Oil Ring End
      *3 No. 1 Compression Ring End
      *4 Oil Ring Expander End
      *5 No. 2 Compression Ring End
      *a for Bank 1
      *b for Bank 2
      B003WAF Engine Front

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

      Note

      Do not align the ring ends.

    3. B003T2AC01
      *1 Front Mark
      *a for Bank 2
      *b for Bank 1
      B003WAF Engine Front

      Using a piston ring compressor, push the correctly numbered piston sub-assembly with connecting rod into the cylinder with the front mark of the piston facing front of the engine.

      Note

      Match the numbered connecting rod cap with the connecting rod.

    4. B003V9HC04
      *1 Front Mark
      B003WAF Engine Front

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

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

    6. Install the connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1


      1. B003V35

        Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps.

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

        Note

        Check that the crankshaft turns smoothly during the procedure.

      2. B003WFZC01
        *1 Paint Mark
        *a 90°
        B003WAF Engine Front

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

    8. Step 2


      1. Tighten the connecting rod bolts 90°.

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

    10. Check that the crankshaft turns smoothly.

  10. INSPECT CONNECTING ROD THRUST CLEARANCE

    Click here