CYLINDER BLOCK REASSEMBLY

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

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 }

Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

Torque:

10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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

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

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.

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

Install the oil ring expander, side rail upper and side rail lower by hand.

Text in Illustration

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*3	Paint Mark
	Top

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

Clean the main journal and both surfaces of the bearing.

Install the lower crankshaft bearing.

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

   Note

   
   

   • Do not apply engine oil to the crankshaft 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 crankshaft bearing with a new one.

Apply engine oil to the crankshaft thrust washer set.

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

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

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

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

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.

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 }

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

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.

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.