CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the piston or piston ring.


PROCEDURE


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


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

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

  2. INSTALL CONNECTING ROD SMALL END BUSH


    1. B0077A6C01
      *a Oil Hole

      Align the oil hole of a new connecting rod small end bush with the oil hole of the connecting rod.

    2. B0076R7E02

      Using SST and a press, push in the connecting rod small end bush.

      SST
      09222-30010
    3. B0073G7

      Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard oil clearance between the connecting rod small end bush and piston pin.

      Standard Oil Clearance
      -0.005 to 0.011 mm (-0.000197 to 0.000433 in.)

    4. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

      Tech Tips

      Check that the piston pin fits at a normal room temperature.

  3. INSTALL PISTON SUB-ASSEMBLY WITH PIN

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston.



    1. B0076AOC06
      *a Cutout

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

      Note

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

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

    3. Coat the piston pin with engine oil.

      CAUTION:

      Be sure to wear protective gloves.

    4. B007348C03
      *a Piston RH
      *b Piston LH
      *c Front Mark

      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.

    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. B00755IC06
      *a Cutout

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

      Note

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

  4. INSTALL PISTON RING SET

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston ring.



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

    2. B0072U5C03
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Code Mark

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.

      Note


      • Install the No. 1 compression ring with the code mark (T1) facing upward.

      • Install the No. 2 compression ring with the code mark (T2) facing upward.

    3. B0072VIC03
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Lower Side Rail
      *4 Upper Side Rail
      *5 Oil Ring Expander
      *a Front Mark

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

      Note

      Do not align the ring ends.

  5. INSTALL CRANKSHAFT BEARING


    1. B0072PRC21
      *a No. 1 and No. 4 Crankshaft Bearing
      *b No. 2 and No. 3 Crankshaft Bearing
      *c 20.9 mm
      *d 17.9 mm

      Clean the main journals and both surfaces of the crankshaft bearings.

      Note

      Crankshaft bearings come in widths of 17.9 mm (0.705 in.) and 20.9 mm (0.823 in.). Install the 20.9 mm (0.823 in.) crankshaft bearings to the No. 1 and No. 4 cylinder block journal positions. Install the 17.9 mm (0.705 in.) crankshaft bearings to the No. 2 and No. 3 positions.

    2. B0076PPC01
      *1 Upper Crankshaft Bearing
      *a Correct
      *b Incorrect

      Install the upper crankshaft bearings.


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

        Note


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

        • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.

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

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

    3. B00774WC11
      *a Vernier Caliper
      *b Number Mark

      Install the lower crankshaft bearings.


      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 lower crankshaft bearing edge.

        Difference Between (A) and (B)
        0.7 mm (0.0276 in.) or less

        Note


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

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

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

  6. INSTALL CRANKSHAFT THRUST WASHER SET


    1. Apply engine oil to the crankshaft thrust washer set.

    2. B0075VUC06
      *a Oil Grooves

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

  7. INSTALL CRANKSHAFT


    1. Apply engine oil to the crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.

    2. B0072T3

      Confirm the projections and numbers of the crankshaft bearing caps and install the 4 crankshaft bearing caps to the cylinder block sub-assembly.

      Tech Tips

      A number is marked on each crankshaft bearing cap to indicate its installation position.

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

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

    5. B00735LC02
      *A Type A
      *B Type B
      *a Less than 6 mm (0.236 in.)
      *b Bolt hole

      Push the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block sub-assembly is less than 6 mm (0.236 in.) by using the 2 inside crankshaft bearing cap set bolts as a guide.

      Tech Tips

      Type A and type B can be distinguished by the shape of the bearing cap bolt.

      Bolt Type
      Type Shape
      A Without threaded hole
      B With threaded hole
    6. B007765

      Using a plastic 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 8 crankshaft bearing cap set bolts.

    8. B0076CRN01

      Install the crankshaft bearing cap bolt (A) and 7 crankshaft bearing cap bolts (B) to the outside positions.

      Tech Tips

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

    9. B0074J8N02

      Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

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

      Tech Tips

      If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

    10. B00781BC07
      *a Paint Mark
      *b Turn 90°
      B0073AQ Front of Engine

      Mark the front of the crankshaft bearing cap set bolts with paint.

    11. Tighten the crankshaft bearing cap set bolts 90° in the order shown in the illustration.

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

    13. B0077VRC01
      *a Bolt Type
      *b Tightening Order

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

      Torque:
      25.7 N*m  { 262 kgf*cm, 19 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt (C) 45 mm (1.77 in.)
      Bolt (D) 30 mm (1.18 in.)

    14. Check that the crankshaft turns smoothly.

    15. Check the crankshaft thrust clearance.

      Click here

  8. INSTALL CONNECTING ROD BEARING


    1. Install the connecting rod bearings to the connecting rod and connecting rod cap.

    2. B0074GVC01
      *a Vernier Caliper

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

      Difference Between (A) and (B)
      0.7 mm (0.0276 in.) or less

      Note

      Do not apply engine oil to the connecting rod bearings or the contact surfaces.

  9. 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. B0072VIC03
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Lower Side Rail
      *4 Upper Side Rail
      *5 Expander
      *a Front Mark

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

      Note

      Do not align the ring ends.

    3. B0076L1C03
      *a for Bank 1
      *b for Bank 2
      *c Front Mark
      B0073AQ Front of Engine

      Using a piston ring compressor, push the piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing the front of the engine.

      Note

      Match the connecting rod cap with the connecting rod sub-assembly.

    4. B00751XC05
      *a Front Mark
      B0073AQ Front of Engine

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

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

    6. Install the 2 connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:


      1. B00732Z

        Alternately tighten the 2 connecting rod bolts in several steps.

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

    8. Step 2:


      1. B00781BC07
        *a Paint Mark
        *b Turn 90°
        B0073AQ Front of Engine

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

      2. Further tighten the connecting rod bolts 90° as shown in the illustration.

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

    9. Confirm that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance.

      Click here