CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

Click here (w/ EGR System)

Click here (w/o EGR System)

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. B003XSCC02
      *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. B003YNVC01
      *1 15709-36010-A
      *2 15709-36020-A

      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-assemblies at the same place it was removed from.

      Tech Tips

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

  3. INSTALL PISTON


    1. B003XU0C02
      *1 Piston Pin Hole Snap Ring (Rear)
      *2 Protective Tape

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

      Tech Tips


      • 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. B003YNCC02
      *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.

      Tech Tips

      Perform "Inspection After Repair" after replacing the piston .

      Click here (w/ EGR System)

      Click here (w/o EGR System)

  4. INSTALL PISTON PIN HOLE SNAP RING


    1. B003YAGC01
      *1 Piston Pin Hole Snap Ring (Front)
      *2 Protective Tape
      *a 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

      Be 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.

      Tech Tips


      • Be 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. INSPECT PISTON WITH CONNECTING ROD


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


      1. A01CZWL

        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


    1. B003YPAC02
      *1 Oil Ring
      *2 Oil Ring Expander
      *a Coil Joint
      *b Oil Ring End
      *c Paint Mark (Blue)
      B003XUN Upward

      Type A


      1. 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.

        • Install the oil ring expander securely to the inner groove in the oil ring.

        • Install the oil ring so that its end with the blue paint mark is positioned to the right of the piston.

      2. B003Y5GC02
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *a Paint Mark
        *b Code Mark
        B003XUN 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 (w/ EGR System)
        Item Code Mark Paint Mark
        No. 1 Compression Ring 1NA Blue
        No. 2 Compression Ring 2N Yellow
        Piston Ring Code Mark (w/o EGR System)
        Item Code Mark Paint Mark
        No. 1 Compression Ring 1N Purple
        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 .

        Click here (w/ EGR System)

        Click here (w/o EGR System)

      3. B003Y5KC03
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *3 Oil Ring
        *4 Oil Ring Expander
        *a Front Mark
        B003XUN Engine Front Side

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

        Tech Tips

        Regardless of the front mark, the piston rings are positioned correctly if their ends are positioned opposite of each other.

    2. B003XZ2C03
      *1 Upper Side Rail
      *2 Oil Ring Expand
      *3 Lower Side Rail
      *a Groove for Upper and Lower Side Rails

      Type B


      1. Install the oil ring expander by hand.

      2. Install the upper and lower side rails by hand.

        Note

        Make sure that the oil ring expander ends do not overlap each other.

        Tech Tips

        Install the oil ring so that its end with the white paint mark is positioned to the right of the piston.

      3. B003Y5GC02
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *a Paint Mark
        *b Code Mark
        B003XUN 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 Black

        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.

        Click here (w/ EGR System)

        Click here (w/o EGR System)

      4. B003YBVC02
        *1 No. 1 Compression Ring and Upper Side Rail
        *2 Oil Ring Expander
        *3 No. 2 Compression Ring and Lowe Side Rail
        *a Front Mark
        B003XUN Engine Front Side

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

        Note

        Regardless of the piston front mark, the positional relation of all ring gaps must be maintained.

        Tech Tips

        End gap of the oil ring expander can also be positioned at "A".

  7. INSTALL CRANKSHAFT BEARING


    1. B003YJVC05
      *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. B003YFMC03
      *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. B003YSEC03
      *1 Crankshaft Bearing Cap
      *2 No. 2 Crankshaft Bearing
      *3 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. B003Y37C03
      *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. B003XSSC03
      *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. B003YP3N02

        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. B003YO6C02
        *a Paint Mark
        *b 90°
        B003XUN Engine Front Side

        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. B003XVJC09
      *1 Connecting Rod Cap
      *2 Connecting Rod Bearing
      *3 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. Check the position of the piston ring ends again.


      1. B003Y5KC04
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *3 Oil Ring
        *4 Oil Ring Expander
        *a Front Mark
        B003XUN Engine Front Side

        Type A

      2. B003YBVC02
        *1 No. 1 Compression Ring and Upper Side Rail
        *2 Oil Ring Expander
        *3 No. 2 Compression Ring and Lowe Side Rail
        *a Front Mark
        B003XUN Engine Front Side

        Type B

        Tech Tips

        End gap of the oil ring expander can also be positioned at "A".

    3. B003YRGC02
      *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. B003YNFC03
      *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. B003Y66C03
        *a Paint Mark
        *b 90°
        B003XUN Engine Front Side

        Mark the front of the connecting rod bolts with paint.

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

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

    9. Check that the crankshaft turns smoothly.