CYLINDER BLOCK REASSEMBLY


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A0119E4

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL PISTON

    A0117I0E03
    Text in Illustration
    *a Front Mark

    1. Gradually heat a new connecting rod to 80°C (176°F) or more.

    2. Coat a new piston pin and pin holes in a new piston with engine oil.

    3. Align the front marks of the piston and connecting rod.

    4. A01175IE03
      Text in Illustration
      *1 Piston Pin
      *2 Connecting Rod
      *3 Piston
      *a Front Mark

      Using SST, press in the piston pin.

      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00090, 09221-00100, 09221-00150 )

      Note


      • Press in the piston pin from the side of the piston with the front mark shown in the illustration.

      • With the connecting rod fully inserted into the piston end, press in the piston pin until it is flush with the piston surface.

    5. 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. A0116ZRE05
      Text in Illustration
      *1 Oil Ring
      *2 Oil Ring Expander
      *3 Coil Joint
      *a Oil Ring Ends

      Install the oil ring expander and oil ring by hand.

      Note


      • Install the expander and oil ring so that their ring ends are at opposite sides.

      • Securely install the expander to the inner groove of the oil ring.

    2. A011A9QE04
      Text in Illustration
      *1 No. 1 Ring
      *2 No. 2 Ring
      *a Upward

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

      Note


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

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

    3. A011AABE03
      Text in Illustration
      *1 Oil Ring
      *2 No. 2 Ring
      *3 No. 1 Ring
      *4 Oil Ring Expander
      A011AXA Front

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

  4. INSTALL CRANKSHAFT BEARING


    1. A011BR3E03
      Text in Illustration
      *a Correct
      *b Incorrect
      A0117XZ Front

      Install the upper bearing.

      Note


      • Align the oil holes on the bearing and cylinder block.

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

    2. Install the lower bearing.


      1. Install the lower bearing onto the bearing cap.

      2. A0119N7E01

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

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

        Note

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

  5. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A01177HE03
      Text in Illustration
      *a Oil Grooves

      Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.

    2. Apply engine oil to the crankshaft thrust washers.

  6. INSTALL CRANKSHAFT

    A011BO2E03

    1. Apply engine oil to the upper bearings and install the crankshaft on the cylinder block.

      Text in Illustration
      *a Number Mark
      A011AXA Front

    2. Apply engine oil to the lower bearings.

    3. Examine the number marks and install the bearing caps on the cylinder block.

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

    5. A0117A9

      Temporarily install the 10 main bearing cap bolts.

    6. Step 1


      1. A0117A9E02

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

        Torque:
        30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    7. Step 2


      1. A011BV6E14
        Text in Illustration
        *a Paint Mark
        A0117XZ Engine Front

        Mark the front of the bearing cap bolts with paint.

      2. Further tighten the bearing cap bolts an additional 90° in the numerical order shown in the previous illustration.

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

    9. Check that the crankshaft turns smoothly.

    10. Check the crankshaft thrust clearance Click here.

  7. INSTALL CONNECTING ROD BEARING

    A01176W

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

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

      Dimension
      2.2 to 2.6 mm (0.0866 to 0.102 in.)

      Note

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

    3. A0117OO

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

      Dimension
      2.2 to 2.6 mm (0.0866 to 0.102 in.)

      Note

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

  8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    A011AABE04

    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.

      Text in Illustration
      *1 Oil Ring
      *2 No. 2 Ring
      *3 No. 1 Ring
      *4 Oil Ring Expander
      A011AXA Front

      Note

      Do not align the ring ends.

    3. A011806E03
      Text in Illustration
      *a Front Mark

      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.

      Note


      • When inserting the piston with connecting rod, do not allow it to make contact with the oil nozzle.

      • Match the numbered connecting rod cap with the connecting rod.

    4. A01173FE05
      Text in Illustration
      *a Front Mark

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

    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.

    7. Step 1


      1. A011A2KE02

        Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.

        SST
        09205-16010
        Torque:
        15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    8. Step 2


      1. A0117O2E13
        Text in Illustration
        *a Paint Mark
        A011AXA Engine Front

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

      2. Further tighten the cap bolts an additional 90° as shown in the illustration.

    9. Check that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance Click here.