CYLINDER BLOCK REASSEMBLY

Tech Tips

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

  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts.

      A011SMJ
      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL PISTON

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

      A011UEXE02
      Text in Illustration
      *1 Service Hole

      Tech Tips

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

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

      A011RH6

    3. Coat the piston pin with engine oil.

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

      A011RSME03
      Text in Illustration
      *a Front Mark

      Tech Tips

      The piston and pin are a matched set.

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

      A011SF1

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

      A011SCSE04
      Text in Illustration
      *1 Service Hole

      Tech Tips

      • Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

      • 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. Using a piston ring expander, install the compression ring as shown in the illustration.

      A011RBBE07
      Text in Illustration
      *1 Piston Ring Expander
      *2 Upper Side Rail
      *3 Oil Ring Expander
      *4 Lower Side Rail
      *5 Oil Ring
      *6 No. 1 Ring
      *7 No. 2 Ring

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

      A011T8QE04
      Text in Illustration
      *1 Lower Side Rail
      *2 No. 2 Ring
      *3 Oil Ring Expander
      *4 No. 1 Ring
      *5 Upper Side Rail
      *a Front Mark

      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. Clean the main journal and both surfaces of the bearings.

      A011QZ2E15
      Text in Illustration
      *1 No. 1 and No. 4 Journal Bearing
      *2 No. 2 and No. 3 Journal Bearing

      Note

      Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

    2. Install the upper crankshaft bearing.

      A011TX1E08

      1. Install the upper crankshaft bearings to the cylinder block as shown in the illustration.

        Text in Illustration
        *1 Upper Bearing
        *a CORRECT
        *b INCORRECT

        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.

    3. Install the lower crankshaft bearing.

      A011V4ZE10
      Text in Illustration
      *1 Vernier Caliper
      *a Mark 1, 2, 3, 4 or 5

      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 the lower crankshaft bearing edge.

        Dimension (A - B)
        0.7 mm (0.0276 in.) or less

        Note

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

  5. INSTALL CRANKSHAFT THRUST WASHER SET

    1. Apply engine oil to the crankshaft thrust washer.

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

      A011T0SE03
      Text in Illustration
      *1 Oil Grooves

  6. INSTALL CRANKSHAFT

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

    2. Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block.

      A011SQ9E04
      Text in Illustration
      *1 Projection
      *a 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 crankshaft bearing cap bolts.

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

    5. Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide.

      A011TSNE06
      Text in Illustration
      *a Less than 6 mm
      *b Bolt Length 100 to 102 mm
      Bolt length
      100 to 102 mm (3.94 to 4.02 in.)

    6. Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

      A011QWT

    7. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.

    8. Install the 8 crankshaft bearing cap bolts to the outside positions.

      A011UO4E05
      Text in Illustration
      *a Bolt Length
      Bolt length
      105.5 to 107.5 mm (4.15 to 4.23 in.)

    9. Install the crankshaft bearing cap bolts.

      Tech Tips

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

    10. Step 1

      1. Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

        A011SZ4E02
        Torque:
        61 N*m  { 622 kgf*cm, 45 ft.*lbf }

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

    11. Step 2

      Text in Illustration
      *a Paint Mark
      *b Turn 90°
      A011V7Q Engine Front

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

        A011RR3E12

      2. Retighten the bearing cap bolts 90° in the sequence shown in the illustration.

      3. Check that the painted mark is now at a 90° angle to the front of the engine.

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

      A011RRXE05
      Torque:
      52 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 bearing to the connecting rod and connecting rod cap.

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

      A011SEEE06
      Text in Illustration
      *1 Vernier Caliper
      Dimension (A - B)
      0.7 mm (0.0276 in.) or less

      Note

      Do not apply engine oil to the bearings and 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. Position the piston rings so that the ring ends are as shown in the illustration.

      A011T8QE04
      Text in Illustration
      *1 Lower Side Rail
      *2 No. 2 Ring
      *3 Oil Ring Expander
      *4 No. 1 Ring
      *5 Upper Side Rail
      *a Front Mark

      Note

      Do not align the ring ends.

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

      A011RJIE03
      Text in Illustration
      *a Front Mark
      A011V7Q Engine Front

      Note

      Match the numbered connecting rod cap with the connecting rod.

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

      A011RE9E07
      Text in Illustration
      *a Front Mark
      A011V7Q Engine Front

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

    6. Install the connecting rod cap bolts.

      Tech Tips

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

    7. Step 1

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

        A011URZ
        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    8. Step 2

      A011SKLE21
      Text in Illustration
      *a Paint Mark
      *b Turn 90°
      A011V7Q Engine Front

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

      2. Retighten the cap bolts 90° as shown in the illustration.

      3. Check that the painted mark is now at a 90° angle to the front.

    9. Confirm that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance Click here.