CYLINDER BLOCK REASSEMBLY

PROCEDURE


  1. INSTALL OIL JET


    1. A005LYME01
      Text in Illustration
      *1 Cylinder block
      *a Upward
      *b Spool

      Install a new oil jet as shown in the illustration.

      Note

      Do not tap the tip of the oil jet.

      Tech Tips

      Press in the oil jet until the spool contacts the cylinder block.

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A005JGG

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

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

  3. INSTALL OIL CHECK VALVE SUB-ASSEMBLY


    1. A005GHC

      Install the oil check valve sub-assembly to the cylinder block.

      Text in Illustration
      A005IBX Crankshaft Bearing Side

      Note


      • Make sure that the oil check valve sub-assembly is not tilted.

      • Install the oil check valve sub-assembly before installing the crankshaft bearing.

      • When installing the crankshaft bearing, make sure it does not interfere with the oil check valve sub-assembly.

  4. INSTALL PISTON

    A005HIQE01

    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.

      Text in Illustration
      *a Front Mark

    4. Using SST, press in the piston pin.

      A005J47E01
      Text in Illustration
      *1 Piston Pin
      *2 Connecting Rod
      *3 Piston
      *a Front Mark
      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.

  5. INSTALL PISTON RING SET


    1. A005MC2E04
      Text in Illustration
      *1 Oil Ring
      *2 Oil Ring Expander
      *3 Coil Joint
      *4 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. A005I2FE01
      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. A005H3JE06
      Text in Illustration
      *1 Oil Ring
      *2 No. 2 Ring
      *3 No. 1 Ring
      *4 Oil Ring Expander
      A005GO2 Engine Front

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

  6. INSTALL CRANKSHAFT BEARING


    1. Install the upper bearing.

      A005I9KE01
      Text in Illustration
      *a Correct
      *b Incorrect
      A005IBX Engine Front

      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. A005JNTE01

        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.

  7. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A005KC8E05
      Text in Illustration
      *1 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.

  8. INSTALL CRANKSHAFT

    A005JJGE04

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

      Text in Illustration
      *a Number Mark
      A005GO2 Engine 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. A005GQS

      Temporarily install the 10 main bearing cap bolts.

    6. Step 1


      1. A005GQSE04

        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. A005M3IE03
        Text in Illustration
        *a Paint Mark
        A005IBX 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.

  9. INSTALL CONNECTING ROD BEARING

    A005LET

    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. A005IOM

      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.

  10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    A005H3JE06

    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
      A005GO2 Engine Front

      Note

      Do not align the ring ends.

    3. A005JOUE05
      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. A005IXUE08
      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. A005LALE02

        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. A005JKOE26
        Text in Illustration
        *a Paint Mark
        A005IBX 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.