БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. A01IJ8QC05
      *a 20 mm (0.787 in.)
      *b 13 mm (0.512 in.)
      *c 35 mm (1.38 in.)

      Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01UCD9

      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 }

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01UFJ1

      Using a 5 mm hexagon wrench, install the 2 No. 1 oil nozzle sub-assemblies with the 2 bolts.

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

  4. INSTALL PISTON

    Tech Tips

    Perform this procedure only when replacement of the piston pin hole snap ring (rear side) is necessary.


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

      Tech Tips

      Tape the screwdriver tip before use.

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

    3. Apply a light coat of engine oil to the piston, piston pin and connecting rod.

    4. A01IJFFC11
      *a Cutout
      *b Front Mark

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

      Note

      Do not change the combination of the pistons and piston pins.

    5. A01IKGJC09
      *1 Piston Pin Hole Snap Ring
      *a Cutout

      Using a screwdriver, install a new piston pin hole snap ring (front side) 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 cutout of the piston.

      • Tape the screwdriver tip before use.

    6. A01IH0B

      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 piston 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 piston pin as a set.

        Tech Tips

        Perform "Inspection After Repair" after replacing the piston.

        Click here

  5. INSTALL PISTON RING SET


    1. A01IKNNC02
      *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.

    2. A01IJHHC06
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Code Mark
      *b Paint Mark
      A01UFKZ 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 Paint Mark
      No. 1 Compression Ring 1NA Blue
      No. 2 Compression Ring 2N Black

      Note

      Install the compression rings with the code marks facing upward.

      Tech Tips

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

      Click here

  6. INSTALL CRANKSHAFT PULLEY KEY


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

  7. INSTALL CRANKSHAFT BEARING


    1. Clean the main journal and both surfaces of the crankshaft bearings and No. 2 crankshaft bearings.

    2. A01IKGIC10
      *a Correct
      *b Incorrect

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

      Note


      • Do not apply engine oil to the crankshaft bearings or 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. A01IIE2C17
      *a Vernier Caliper

      Install the No. 2 crankshaft bearings to the crankshaft bearing caps.

    4. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and No. 2 crankshaft bearing edge.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.

      • 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 CRANKSHAFT THRUST WASHER


    1. A01UFC2C14
      *a Oil Groove

      Apply engine oil to the crankshaft thrust washers.

    2. Install the 2 crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

  9. INSTALL CRANKSHAFT


    1. A01IL9QC07
      *a Front Mark

      Apply engine oil to the crankshaft bearings, and place the crankshaft on the cylinder block sub-assembly.

    2. Apply engine oil to the No. 2 crankshaft bearings.

    3. Confirm the front marks and numbers, and install the 5 crankshaft bearing caps to the cylinder block sub-assembly with the front marks positioned as shown in the illustration.

      Tech Tips

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

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

    5. Step 1:


      1. A01IJ7GN10

        Uniformly install and tighten the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    6. Step 2:


      1. Further tighten the 10 crankshaft bearing cap bolts again in the order shown in the illustration.

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

        If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

    7. Step 3:


      1. A01IJ2GC04
        *a Paint Mark
        *b 90°
        A01UFKZ Front of Engine

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

      2. Tighten the 10 crankshaft bearing cap bolts 90° as shown in the illustration.

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

    8. Check that the crankshaft turns smoothly.

  10. INSTALL CONNECTING ROD BEARING


    1. A01IFB6C19
      *a Vernier Caliper

      Clean the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap, and both surfaces of the 2 connecting rod bearings.

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

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

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • Do not apply engine oil to the connecting rod bearings or 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.

    2. A01IL8QC04
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring Expander
      *4 Upper Oil Ring Side Rail
      *5 Lower Oil Ring Side Rail

      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.

    3. A01IFZTC02
      *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 the front of the engine.

      Note

      When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the No. 1 oil nozzle sub-assembly does not interfere with the connecting rod.

    4. A01IHOVC04
      *a Front Mark

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

      Note

      Match the connecting rod cap with the connecting rod.

    5. A01UF7B

      Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

    6. Temporarily install the 2 connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    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. A01IJX2C13
      *a Paint Mark
      *b 90°
      A01UFKZ Front of Engine

      Step 2:


      1. 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 marks are now at a 90° angle to the front.

    9. Check that the crankshaft turns smoothly.