БЛОК ЦИЛИНДРОВ ПОВТОРНАЯ СБОРКА

Информация добавлена 08-08-2017

PROCEDURE


  1. INSTALL STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. Using E6, E7 and E8 "TORX" socket wrenches, 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 }
      A01A2SAC02
      *a Front Side *b Upper Side
      *c Lower Side *d Rear Side

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. 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 CONNECTING ROD SMALL END BUSH


    1. A01A56YC01
      *1 Oil Hole

      Align the oil holes of a new bush and the connecting rod.

    2. A01A8CCN01

      Using SST and a press, press in the bush.

      SST
      09222-30010
    3. A01A68U

      Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.

      Standard oil clearance
      -0.002 to 0.004 mm (-0.0000787 to 0.000156 in.)

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

      Tech Tips

      The piston and pin are a matched set.

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

  4. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A01A7F0C01
      *1 Cutout Portion

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

    3. A01A81KC02
      *1 Front Mark

      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.

      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. A01A2TRC01
      *1 Cutout Portion

      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.

  5. INSTALL PISTON RING SET


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

    2. A01A42NC02
      *1 Painted Mark
      *2 No. 1 Compression Ring
      *3 No. 2 Compression Ring
      B001T99 Right Side

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

      Tech Tips

      Install each compression ring with the painted mark facing towards the right side.

    3. A01A6Y0C01
      *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.

  6. INSTALL CRANKSHAFT BEARING

    A01A4B5C01
    *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. A01A5TDC01
      *a CORRECT
      *b INCORRECT

      Install the upper bearing.


      1. 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. A01A4KBC01
      *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.

  7. 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. A01A58U

      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. A01A6K4

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

    5. A01A3KO

      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. A01A8S1C01
      *a Less than 6 mm (0.236 in.)

      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. A01A6G5

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

    10. A01A30B

      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. A01A7QYN01

        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 marks are now at a 90° angle to the front.

    12. Check that the crankshaft turns smoothly.

    13. A01A5MGC01
      B001T99 Bolt A
      B001PIP Bolt B

      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.)

    14. Check that the crankshaft turns smoothly.

  8. INSTALL CONNECTING ROD BEARING


    1. A01A787C01
      *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. A01A5J6C01
      *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.)

  9. INSPECT CRANKSHAFT THRUST CLEARANCE

    Click here

  10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A01A6Y0C02
      *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. A01A4E9C02
      *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. A01A70KC02
      *1 Protrusion
      B001T99 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. A01A6Z2

        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 marks are now at a 90° angle to the front.

    7. Check that the crankshaft turns smoothly.

  11. INSPECT CONNECTING ROD THRUST CLEARANCE

    Click here