CYLINDER BLOCK REASSEMBLY


  1. INSTALL STUD BOLT

    Note

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


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

      A01557IE04
      Text in Illustration
      *A Upper Side *B Lower Side
      Torque:
      for stud bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for stud bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.

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

  3. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A015DFNE02
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

      Be sure that the end gap of the snap ring is not aligned with the service hole of the piston.

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

    3. Coat the piston pin and connecting rod with engine oil.

    4. A0159DUE03
      Text in Illustration
      *A LH
      *B RH
      *1 Front Mark

      Align the front marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the snap ring.

      Note

      For the LH side, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For the RH side, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides.

      Tech Tips

      The piston and pin are a matched set.

    5. 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 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.

    6. A015DFNE02
      Text in Illustration
      *1 Service Hole

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

      Tech Tips

      Be sure that the end gap of the snap ring is not aligned with the service hole of the piston.

  4. INSTALL PISTON RING SET


    1. A015E3UE03
      Text in Illustration
      *1 Side Rail Upper
      *2 Side Rail Lower
      *3 Oil Ring Expander

      Install the oil ring expander and 2 side rails by hand.

    2. A015A3DE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Paint Mark
      A015DIT Top

      Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.

      Paint Mark
      Item Paint Mark
      No. 1 compression ring Yellow
      No. 2 compression ring Green

  5. INSTALL CRANKSHAFT BEARING


    1. A0157TXE21
      Text in Illustration
      *1 No. 1 and No. 5 Journal Bearings
      *2 No. 2, No. 3 and No. 4 Journal Bearings

      Clean the main journal and both surfaces of the bearing.

    2. Install the upper bearing.

      Note

      Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.


      1. A015BZ2E03
        Text in Illustration
        *a CORRECT
        *b INCORRECT

        Install the upper bearing to the cylinder block as shown in the illustration.

        Note


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

        • Both sides of the oil groove in the cylinder block 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. A0159HZE06
      Text in Illustration
      *1 Vernier Caliper

      Install the lower bearing.

      Note


      • Be sure to install the selected bearing.

      • Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.


      1. Install the lower bearings to the crankshaft bearing caps.

      2. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower bearing edge.

        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.

  6. INSTALL CRANKSHAFT THRUST WASHER SET


    1. Apply engine oil to the thrust washer set.

    2. Install the 4 thrust washers to the No. 3 journal position of the cylinder block and crankshaft bearing cap with the oil grooves facing outward.

  7. INSTALL CRANKSHAFT


    1. A0157NRE03

      Apply engine oil to the upper bearing and lower bearing, then place the crankshaft on the cylinder block.

    2. Confirm the front marks and numbers of the crankshaft bearing caps, and install the crankshaft bearing caps on the cylinder block.

      Text in Illustration
      *1 Number Mark

      Tech Tips

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

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

    4. Temporarily install the 10 crankshaft bearing cap bolts to the inside positions.

    5. A01555QE03
      Text in Illustration
      *a Less than 6 mm

      Push the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block is less than 6 mm (0.236 in.).

      Bolt length
      91 mm (3.58 in.)
    6. A015AH5E01

      Using a plastic-faced 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 10 crankshaft bearing cap bolts.

    8. A0157I6E01

      Temporarily install the 10 crankshaft bearing cap bolts to the outside positions.

      Bolt length
      79.5 mm (3.13 in.)

      Tech Tips

      The main bearing cap bolts are tightened in 2 progressive steps.

    9. Step 1:


      1. A0157LDE02

        Uniformly tighten the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.

        Torque:
        for inside position
        61 N*m  { 622 kgf*cm, 45 ft.*lbf }
        for outside position
        27 N*m  { 275 kgf*cm, 20 ft.*lbf }

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

    10. Step 2:


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

      2. Tighten the bearing cap bolts 90° in the order shown in step 1.

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

    11. Check that the crankshaft turns smoothly.

    12. A015CZSE01

      Install and uniformly tighten the 10 crankshaft bearing cap bolts and 10 new seal washers in several steps in the sequence shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

    13. Check that the crankshaft turns smoothly.

  8. INSTALL CONNECTING ROD BEARING

    A015B4XE02
    Text in Illustration
    *1 Vernier Caliper

    1. Install the connecting rod bearings to the connecting rods and bearing caps.

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

      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.

  9. INSTALL PISTON AND CONNECTING ROD


    1. A0156L6E03

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

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

      Text in Illustration
      *1 Side Rail Upper
      *2 Side Rail Lower
      *3 Front Mark
      *4 No. 1 Ring
      *5 No. 2 Ring

      Note

      Do not align the ring ends.

      Tech Tips

      The expander ends can be placed anywhere.

    3. A0156XJE04
      Text in Illustration
      *A LH
      *B RH
      *1 Front Mark

      Using a hammer handle and piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward.

    4. Place the connecting rod cap on the connecting rod.


      1. A015AMXE02
        Text in Illustration
        *1 Front Mark
        A015DIT Front

        Match the numbered connecting rod cap with the connecting rod.

      2. Place the connecting rod cap on the connecting rod, and check that the front mark of the connecting rod cap is facing the direction indicated in the chart below.

        Front Mark
        Item Front Mark
        Bank 1 Front side
        Bank 2 Rear side

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

    6. Temporarily install the connecting rod cap bolts.

      Tech Tips

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

    7. Step 1:


      1. A015CRM

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

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

    8. Step 2:


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

      2. Tighten the cap bolts 90° as shown in the illustration in the order in step 1.

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

    9. Check that the crankshaft turns smoothly.