CYLINDER BLOCK REASSEMBLY

Tech Tips

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


  1. INSTALL STUD BOLT

    Note

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


    1. Using an E8 and E10 "TORX" socket wrench, install the stud bolts.

      A01G6QOE05
      Text in Illustration
      *a RH Side *b LH Side
      Torque:
      for stud bolt A
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      for stud bolt B
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01G5OW

      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. A01G4VD

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

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

  4. INSTALL PISTON


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

    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.

    4. A01G9LZE04
      Text in Illustration
      *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 pin comes into contact with the snap ring.

      Tech Tips

      The piston and pin are a matched set.

    5. A01G5RIE05
      Text in Illustration
      *1 Piston Pin Hole Snap Ring
      *a Front Mark Cutout Portion

      Using a small 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 front mark cutout portion of the piston.

    6. A01G4Y2

      Check the fitting condition between the piston and piston pin.


      1. Move the connecting rod sub-assembly 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 pin as a set.

        Tech Tips

        Perform "Inspection After Repair" after replacing the piston Click here.

  5. INSTALL PISTON RING SET


    1. A01G8TME04
      Text in Illustration
      *1 Oil Ring
      *2 Oil Ring Expander
      *3 Coil Joint
      *4 Oil Ring End

      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.

    2. A01G47OE05
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Code Mark
      *b Paint Mark
      A01G8AH 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 1N Blue
      No. 2 Compression Ring 2N Orange

      Note

      Install the compression ring with the code mark facing upward.

      Tech Tips

      Perform "Inspection After Repair" after replacing the piston, piston ring Click here.

  6. INSTALL CRANKSHAFT PULLEY KEY


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

  7. INSTALL CRANKSHAFT BEARING


    1. A01G7WEE03
      Text in Illustration
      *a CORRECT
      *b INCORRECT

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

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

      Note


      • Do not apply engine oil to the bearings or their contact surfaces.

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

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

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

    3. A01G8U5E02
      Text in Illustration
      *1 Vernier Caliper

      Install the No. 2 crankshaft bearing onto the crankshaft bearing cap.

    4. 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


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

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

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

  8. INSTALL CRANKSHAFT THRUST WASHER


    1. A01G70LE02
      Text in Illustration
      *1 Oil Groove

      Apply engine oil to the crankshaft thrust washers.

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

  9. INSTALL CRANKSHAFT


    1. A01G7KHE01
      Text in Illustration
      *a Front Mark

      Apply engine oil to the crankshaft bearing, and install the crankshaft onto the cylinder block sub-assembly.

    2. Examine the front marks and numbers, and install the crankshaft bearing caps onto the cylinder block sub-assembly with the front marks as shown in the illustration.

      Tech Tips

      The crankshaft bearing cap 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 bolts.

    4. Step 1:


      1. A01G9KXE02

        Using several steps, uniformly install and tighten the 10 crankshaft bearing cap 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 bolts again in the sequence shown in the illustration.

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

        If a crankshaft bearing cap bolt does not meet the specified torque, replace it.

    6. Step 3:


      1. A01G4MAE05
        Text in Illustration
        *a Paint Mark
        A01G47H Engine Front

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

      2. Tighten the 10 crankshaft bearing cap 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. A01G8U1E02
      Text in Illustration
      *1 Vernier Caliper

      Clean the connecting rod bearing contact surface of the connecting rod sub-assembly and connecting rod cap, and both surfaces of both connecting rod bearings.

    2. Install the connecting rod bearings to the connecting rod sub-assemblies and connecting rod caps.

    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 bearing 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. A01G9ABE05
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *4 Oil Ring (Expander)
      *a Front Mark
      A01G8AH Engine Front

      Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

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

    3. A01G6UEE04
      Text in Illustration
      *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 forward.

      Note

      When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the oil nozzle does not interfere with the connecting rod sub-assembly.

      Tech Tips

      The front mark is "2L" printed in raised letters.

    4. A01G9B3E02
      Text in Illustration
      *a Front Mark

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

      Note

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

    5. A01G48F

      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. A01G6MOE25
      Text in Illustration
      *a Paint Mark
      A01G47H Engine Front

      Step 2:


      1. Mark the front of the 2 connecting rod bolts with paint.

      2. Tighten the 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.