CYLINDER BLOCK REASSEMBLY


  1. INSTALL STUD BOLT


    1. Install new stud bolts.

      Torque:
      for stud bolt A and C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for stud bolt B and D
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      A00JU72E01
      Text in Illustration
      *A Front Side *B Upper Side
      *C Lower Side *D Rear Side

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A00JXM7

      Using a 5 mm hexagon socket wrench, install the 3 oil nozzles with the 3 bolts.

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

  3. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A00JWJP

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

      Tech Tips

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

    2. A00K06NE12

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

    3. A00JWNME01

      Coat the piston pin with engine oil.

    4. Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the pin comes into contact with the snap ring.

      Text in Illustration
      *1 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.

    6. A00JV3M

      Using a 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 pin hole cutout portion of the piston.

  4. INSTALL PISTON RING SET


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

    2. A00JXHHE01
      Text in Illustration
      *1 Painted Mark
      *2 No. 1 Compression Ring
      *3 No. 2 Compression Ring
      A00JWY4 Right Side

      Using a piston ring expander, install the 2 compression rings with the painted mark on the right side.

    3. A00JYZBE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Lower Side Rail
      *4 Upper Side Rail
      *5 Expander
      *6 Front Mark

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

  5. INSTALL CRANKSHAFT BEARING

    A00JVB1E01
    Text in Illustration
    *1 No. 1 and No. 4 Journal Bearings
    *2 No. 2 and No. 3 Journal Bearings

    Tech Tips

    Main bearings come in widths of 17.3 mm (0.681 in.) and 19.9 mm (0.783 in.). Install the 19.9 mm (0.783 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the bearing caps. Install the 17.3 mm (0.681 in.) bearings in the No. 2 and No. 3 positions.


    1. Clean each main journal and bearing.

    2. Install the upper bearing.


      1. A00JVY1E02
        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 or 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 inner surface of the bearing.

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

    3. A00JWWOE02
      Text in Illustration
      *1 Mark 1, 2, 3 or 4
      *2 Vernier Caliper

      Install the lower bearing.


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

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

        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 or contact surfaces.

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

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

  6. INSTALL CRANKSHAFT

    Note

    Clean the contact surface of each main journal and crank pin.


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

    2. A00JUGC

      Push the crankshaft in the rear thrust direction to create clearance and install a thrust washer to the No. 2 journal position with the oil groove facing the front of the engine.

    3. Push the crankshaft in the forward thrust direction to create clearance and install a thrust washer to the No. 2 journal position with the oil groove facing the rear of the engine.

    4. A00JU1A

      Install the 2 lower thrust washers to the No. 2 bearing cap with the grooves facing outward.

    5. A00JXBO

      Examine the front marks and numbers and set the crankshaft bearing caps on the cylinder block.

    6. Apply a light coat of engine oil to the threads of the crankshaft bearing cap bolts.

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

    8. A00JZ7GE01
      Text in Illustration
      *a Less than 6 mm

      Tighten the 2 bolts for each bearing cap until the clearance between the crankshaft bearing cap and the cylinder block becomes less than 6 mm (0.236 in.).

    9. A00JWAJ

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

    10. A00JVWXE01

      Apply a light coat of engine oil to the threads of the crankshaft bearing cap bolts and temporarily install the 8 crankshaft bearing bolts to the outside positions.

    11. Tighten the crankshaft bearing cap bolts.

      Tech Tips

      The cap bolts are tightened in 2 progressive steps.


      1. A00JUHJE01

        Step 1:

        Uniformly tighten the 16 bolts in several steps in the order shown in the illustration.

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

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

      3. Step 2:

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

      4. Check that the paint mark is now at a 90° angle to the front.

    12. Check that the crankshaft turns smoothly.

    13. A00JYN8E01

      Install and uniformly tighten the 8 main bearing cap bolts together with 8 new seal washers in several steps in the sequence shown in the illustration.

      Torque:
      26 N*m  { 262 kgf*cm, 19 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 45 mm (1.77 in.)
      Bolt B 30 mm (1.18 in.)
      Text in Illustration
      A00JWY4 Bolt A
      A00JYOS Bolt B

    14. Check that the crankshaft turns smoothly.

  7. INSTALL CONNECTING ROD BEARING


    1. A00JY4GE02
      Text in Illustration
      *1 Vernier Caliper
      *2 Connecting Rod Cap
      *3 Connecting Rod Bearing

      Install the bearing to the connecting rod cap.

      Note


      • Clean the contact surfaces of the bearing and connecting rod cap.


      • Do not apply engine oil to the bearing or the surface it contacts.

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

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)
    3. A00JZBJE02
      Text in Illustration
      *1 Vernier Caliper
      *2 Connecting Rod
      *3 Connecting Rod Bearing

      Install the bearing to the connecting rod.

      Note


      • Clean the contact surface of the bearing and connecting rod.


      • Do not apply engine oil to the bearing or the surface it contacts.

    4. Using a vernier caliper, measure the distance between the connecting rod edge and connecting rod bearing edge.

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  8. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A0096N7

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the thrust washers as a set.

      Standard thrust washer thickness
      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

      If necessary, replace the crankshaft.

  9. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A00JYZBE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Lower Side Rail
      *4 Upper Side Rail
      *5 Expander
      *6 Front Mark

      Check the positions of the piston ring ends.

    3. A00JYGDE01
      Text in Illustration
      *1 Front Mark

      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.

    4. A00K00EE02
      Text in Illustration
      *1 Protrusion
      A00JWY4 Front

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

      Note

      Match each numbered connecting rod cap with the correct connecting rod.

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

    6. Install the connecting rod cap bolts.

      Tech Tips

      The cap bolts are tightened in 2 progressive steps.


      1. A00JUDQE01

        Step 1:

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

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }

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

      3. Step 2:

        Tighten the cap bolts 90°.

      4. Check that the paint mark is now at a 90° angle to the front.

    7. Check that the crankshaft turns smoothly.

  10. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A0096HI

      Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.15 to 0.30 mm (0.00591 to 0.0118 in.)
      Maximum thrust clearance
      0.35 mm (0.0138 in.)

      If the thrust clearance is more than the maximum, replace one or more connecting rods as necessary.

      Standard connecting rod thickness
      20.80 to 20.85 mm (0.819 to 0.821 in.)

      If necessary, replace the crankshaft.