БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

  1. INSTALL STUD BOLT

    1. Install the 8 stud bolts into the cylinder block.

      A00DTGTE04
      Torque:
      for bolt A
      22 N*m  { 219 kgf*cm, 16 ft.*lbf }
      for bolt B and D
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for bolt C
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  2. INSTALL PISTON WITH PIN SUB-ASSEMBLY

    1. A00DPIPE02

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

      Tech Tips

      Make sure 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 80 to 90°C (176 to 194°F).

    3. A00DTNME02

      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

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

    4. A00DRGE

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

  3. INSTALL PISTON RING SET

    1. A00DPX8E01

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

      Text in Illustration
      *1 Upper Side Rail
      *2 Lower Side Rail
      *3 Oil Ring Expander
    2. A00DQLIE05

      Using a piston ring expander, install the 2 compression rings with the paint mark as shown in the illustration.

      Note

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

    3. A00DTPDE01

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

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

  4. INSTALL CRANKSHAFT BEARING

    1. A00DRTGE02

      Install the upper bearing to the cylinder block.

      Tech Tips

      Upper bearings have an oil groove and oil hole; lower bearings do not.

      Note

      Do not apply engine oil to the contact surfaces of the cylinder block and crankshaft bearing.

  5. INSTALL NO. 2 CRANKSHAFT BEARING

    1. A00DT16E01

      Install the lower bearing onto the bearing cap.

      Note

      Do not apply engine oil to the contact surfaces of the cylinder block and crankshaft bearing cap.

  6. INSTALL CRANKSHAFT THRUST WASHER UPPER

    1. A00DS6YE05

      Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil groove facing outward.

      Text in Illustration
      *1 Oil Groove

      Note

      Make sure to install the proper thrust washers.

    2. Apply engine oil to the crankshaft thrust washers.

  7. INSTALL CRANKSHAFT

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

    2. Apply engine oil to the lower bearings.

    3. A00DUVJE02

      Examine the front marks and numbers, and install the bearing caps onto the cylinder block in the order shown in the illustration.

      Text in Illustration
      *1 Front Mark

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

    5. Install the crankshaft bearing cap bolts.

      Note

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

    6. Step 1:

      1. A00DQ8JE02

        Install and uniformly tighten the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

        Torque:
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    7. Step 2:

      1. A00DSG0E04

        Mark the front of the bearing cap bolts with paint.

      2. Tighten the 10 bearing cap bolts by 90° in the same sequence as step 1.

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

    9. Check that the crankshaft turns smoothly.

    10. Check the crankshaft thrust clearance Click here.

  8. INSTALL CONNECTING ROD BEARING

    1. A00DSM0E02

      Align the bearing claw with the oil groove of the connecting rod or connecting rod cap and install the bearing.

      Text in Illustration
      *1 Claw

      Note

      Do not apply engine oil to the bearing inner surface or connecting rod contact surface.

  9. INSTALL PISTON WITH CONNECTING ROD

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

    2. A00DTPDE01

      Check the position of the piston ring ends.

      Text in Illustration
      *1 No. 1 Compression
      *2 No. 2 Compression
      *3 Upper Side Rail
      *4 Front Mark
      *5 Expander
      *6 Lower Side Rail
    3. A00DSADE06

      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.

      Text in Illustration
      *1 Front
      *2 Front Mark
      *3 Hammer Handle

      Note

      Match the numbered connecting rod cap with the connecting rod.

    4. A00DR1ME03

      Check that the front mark of the connecting rod cap is facing in the correct direction and install the cap.

      Text in Illustration
      *1 Front Mark

    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.

      Note

      The connecting rod cap bolts should be tightened in 2 progressive steps.

      1. Step 1:

        Using a 12 mm socket wrench, tighten the bolts to the specified torque in several passes.

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

      2. Step 2:

        A00DSG0E04

        Mark the front of the connecting rod cap bolts with paint.

        Tighten the rod cap bolts 90° as shown in the illustration.

    7. Check that the crankshaft turns smoothly.

    8. Check the connecting rod thrust clearance Click here.