CYLINDER BLOCK REASSEMBLY

Install 2 new gaskets and the 2 straight screw plugs.

Torque:

38 N*m  { 387 kgf*cm, 28 ft.*lbf }

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 }

Using a screwdriver, install a new snap ring on one side of the piston pin hole.

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

RH:

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

   Tech Tips

   
   

   • The piston and pin are a matched set.

   • The piston has 2 front marks.

LH:

1. Face the front marks of the piston and connecting rod in opposite directions, and push in the piston pin with your thumb.

   Tech Tips

   
   

   • The piston and pin are a matched set.

   • The piston has 1 front mark.

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

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

Install the oil ring expander by hand.

Using a piston ring expander, install the oil ring.

Using a piston ring expander, install the No. 1 and No. 2 compression rings so that the code marks are positioned as shown in the illustration.

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

Align the bearing claw with the claw groove of the connecting rod cap.

Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper crankshaft bearings.

Align the bearing claw with the claw groove of the bearing cap, and push in the 5 lower crankshaft bearings.

Apply new engine oil to the upper crankshaft bearing and install the crankshaft to the cylinder block.

Push the crankshaft toward the rear thrust direction to create clearance, and install a thrust washer to the No. 3 journal position with the oil groove facing the front of the engine.

Examine the front marks and numbers and install the bearing caps to the cylinder block.

Temporarily install the crankshaft bearing cap bolts labeled A or the bolts labeled B.

Set the 2 cylinder block stiffening plates on the cylinder block.

Step 1:

1. Apply a light coat of engine oil to the threads and under the heads of the 20 crankshaft bearing cap bolts A and B.

2. Install the 20 crankshaft bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.

   Torque:

   for bolt A

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

   for bolt B

   60 N*m  { 612 kgf*cm, 44 ft.*lbf }

Step 2:

1. Mark the front side of the crankshaft bearing cap bolts A and B with paint.

2. Tighten the crankshaft bearing cap bolts A and B 90° in the sequence shown in the illustration.

Step 3:

1. Tighten the crankshaft bearing cap bolts A another 90° in the sequence shown in the illustration.

Check that the painted marks of bolt A are now at a 180° angle to the front.

Check that the painted marks of bolt B are now at a 90° angle to the front.

Step 4:

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

   Torque:

   56 N*m  { 571 kgf*cm, 41 ft.*lbf }

2. Check that the crankshaft turns smoothly.

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

Using a hammer handle and piston ring compressor, press a piston and connecting rod assembly into each cylinder with the front mark of the piston facing forward.

Install the connecting rod cap so that its protrusion is facing the correct direction.

Step 2:

1. 

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

2. Tighten the cap bolts 90°.

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