CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B006PXP

      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 PISTON


    1. B006P1CC03
      *a Cutout

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

      Note

      Make sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston pin hole.

    2. B006OXW

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

    3. Coat the piston pin with engine oil.

      CAUTION:

      Be sure to wear protective gloves.

    4. B006PW3C03
      *a Front Mark

      Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb.

      Tech Tips

      The piston and piston pin are a matched set.

    5. B006KIN

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

      Tech Tips

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

    6. B006P53C03
      *a Cutout

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

      Note

      Make sure that the end gap of the snap ring is not aligned with the cutout of the piston pin hole.

      Tech Tips

      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. B006OWZC03
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *a Piston Ring Expander
      *b Upper Side Rail
      *c Oil Ring Expander
      *d Lower Side Rail
      *e Cutout

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.

      Note


      • The No. 1 compression ring can be installed with either side facing upward.

      • Install the No. 2 compression ring with the cutout facing downward.

    3. B006QRIC07
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Front Mark
      *b Lower Side Rail
      *c Oil Ring Expander
      *d Upper Side Rail

      Position the piston ring set 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. B006NLJC13
      *a No. 1 and No. 4 Crankshaft Bearing
      *b No. 2 and No. 3 Crankshaft Bearing
      *c 21.0 mm (0.827 in.)
      *d 18.0 mm (0.709 in.)

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

      Note

      Crankshaft bearings come in widths of 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) crankshaft bearings to the No. 1 and No. 4 cylinder block journal positions. Install the 18.0 mm (0.709 in.) crankshaft bearings to the No. 2 and No. 3 positions.

    2. B006OS7C01
      *a Upper Crankshaft Bearing
      *b Correct
      *c 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 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. B006P35C04
      *a Vernier Caliper
      *b 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 lower crankshaft bearing edge.

        Difference Between (A) and (B)
        0.7 mm (0.0276 in.) or less

        Note


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

  5. INSTALL CRANKSHAFT THRUST WASHER SET


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

    2. B006Q3KC05
      *a Oil Groove

      Install the crankshaft thrust washer set 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 crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.

    2. B006KMWC07
      *a Projection
      *b Number Mark

      Confirm the projections and numbers of the crankshaft bearing caps and install the 4 crankshaft bearing caps to the cylinder block sub-assembly.

      Tech Tips

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

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

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

    5. B006KV2C04
      *a Less than 6 mm
      *b Bolt Length 100 to 102 mm

      Push 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 using the 2 inside crankshaft bearing cap set bolts as a guide.

      Bolt Length
      100 to 102 mm (3.94 to 4.02 in.)
    6. B006QV1

      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 set bolts.

    8. B006L9RC03
      *a Bolt Length

      Temporarily install the 8 crankshaft bearing cap set 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 set bolts.

      Tech Tips

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

    10. Step 1:


      1. B006OELN03

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

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

        Tech Tips

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

    11. Step 2:


      1. B006O5GC01
        *a Paint Mark
        *b Turn 90°
        B006LKF Front of Engine

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

      2. Tighten the crankshaft bearing cap set bolts 90° in the order shown in the illustration.

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

    12. B006RIQN02

      Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

      Torque:
      51.5 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 bearings to the connecting rod sub-assembly and connecting rod cap.

    2. B006MPPC01
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the connecting rod sub-assembly and connecting rod cap edges and the connecting rod bearing edge.

      Difference Between (A) and (B)
      0.7 mm (0.0276 in.) or less

      Note

      Do not apply engine oil to the connecting rod bearings or 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. B006QRIC07
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Front Mark
      *b Lower Side Rail
      *c Oil Ring Expander
      *d Upper Side Rail

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

      Note

      Do not align the ring ends.

    3. B006QYIC04
      *a Front Mark
      B006LKF Front of Engine

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

      Note

      Match the connecting rod cap with the connecting rod sub-assembly.

    4. B006MAOC02
      *a Front Mark
      B006LKF Front of Engine

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

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

    6. Install the 2 connecting rod cap bolts.

      Tech Tips

      The connecting rod cap bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. B006KI2

        Alternately tighten the 2 connecting rod cap bolts in several steps.

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    8. B006NIIC52
      *a Paint Mark
      *b Turn 90°
      B006LKF Front of Engine

      Step 2:


      1. Mark the front of each connecting rod cap bolt with paint.

      2. Further tighten the connecting rod cap bolts 90° as shown in the illustration.

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

    9. Confirm that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance.

      Click here