CYLINDER BLOCK REASSEMBLY


  1. INSTALL RING PIN


    1. Using a plastic hammer, tap in the ring pins.

      A01EVVTE01
      Text in Illustration
      *a Upper Side *b Lower Side
      *c Protrusion Height - -
      Standard Protrusion
      Item Protrusion
      A 6 mm (0.236 in.)
      B 5 mm (0.197 in.)

  2. INSTALL STUD BOLT


    1. A01EWF7E04
      Text in Illustration
      *a RH Side

      Using an E7 "TORX" socket, install the stud bolt.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  3. INSTALL STRAIGHT PIN


    1. Using a plastic hammer, tap in the straight pins.

      A01ESU0E04
      Text in Illustration
      *a Front Side *b Lower Side
      *c Rear Side *d RH Side
      *e LH Side *f Protrusion Height
      Standard Protrusion
      Item Protrusion
      A 8 mm (0.315 in.)
      B 7.5 mm (0.295 in.)
      C 12 mm (0.472 in.)
      D 5 mm (0.197 in.)

  4. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Check the crank journal and bearing for pitting and scratches.

    2. Install the crankshaft bearing Click here.

    3. Place the crankshaft on the cylinder block.

    4. A01EVNAE05
      Text in Illustration
      *1 Plastigage

      Lay a strip of plastigage across each journal.

    5. Examine the front marks and numbers and install the crankshaft bearing caps on the cylinder block.

      Tech Tips

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

    6. Install the crankshaft bearing caps Click here.

      Note

      Do not turn the crankshaft.

    7. Remove the bearing caps Click here.

    8. A01ETTXE08
      Text in Illustration
      *1 Plastigage
      *a Number Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.008 to 0.024 mm (0.000315 to 0.000945 in.)
      Maximum oil clearance
      0.05 mm (0.00197 in.)

      Note

      Remove the Plastigage completely after the measurement.

      If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

      Tech Tips


      • If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

      • EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3")

      Cylinder block + Crankshaft 0 to 2 3 to 5 6 to 8 9 to 11
      Bearing to be used "1" "2" "3" "4"
      Standard Cylinder Block Journal Bore Diameter
      Mark Specified Condition
      0 59.000 to 59.002 mm (2.32283 to 2.32291 in.)
      1 59.003 to 59.004 mm (2.32295 to 2.32299 in.)
      2 59.005 to 59.006 mm (2.32303 to 2.32307 in.)
      3 59.007 to 59.009 mm (2.32311 to 2.32318 in.)
      4 59.010 to 59.011 mm (2.32322 to 2.32326 in.)
      5 59.012 to 59.013 mm (2.32330 to 2.32334 in.)
      6 59.014 to 59.016 mm (2.32338 to 2.32346 in.)
      Standard Crankshaft Journal Diameter
      Mark Specified Condition
      0 54.999 to 55.000 mm (2.16531 to 2.16535 in.)
      1 54.997 to 54.998 mm (2.16523 to 2.16527 in.)
      2 54.995 to 54.996 mm (2.16515 to 2.16519 in.)
      3 54.993 to 54.994 mm (2.16507 to 2.16511 in.)
      4 54.991 to 54.992 mm (2.16500 to 2.16504 in.)
      5 54.988 to 54.990 mm (2.16488 to 2.16496 in.)
      Standard Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.993 to 1.996 mm (0.078464 to 0.078583 in.)
      2 1.997 to 1.999 mm (0.078622 to 0.078701 in.)
      3 2.000 to 2.002 mm (0.078740 to 0.078819 in.)
      4 2.003 to 2.005 mm (0.078858 to 0.078937 in.)

  5. INSTALL PISTON


    1. A01EYD3

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

      Tech Tips

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

    2. Gradually heat the piston to approximately 80 to 90 °C (176 to 194°F).

    3. A01EWCQE03
      Text in Illustration
      *1 Front Mark

      Align the front marks on the piston and connecting rod, and push in the piston with a thumb.

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

      Tech Tips

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

    5. A01EWNH

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

  6. INSTALL PISTON RING SET


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

    2. A01EXXIE06
      Text in Illustration
      *1 Piston Ring Expander
      *a Paint Mark
      *b Code Mark (T)
      A01EUL1 Upward

      Using a piston ring expander, install the 2 compression rings.

      Note

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

      Tech Tips

      The No. 1 compression ring can be installed with either side facing upward.

    3. A01EXS0E02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Oil Ring Side Rail
      *4 Oil Ring Expander
      *5 Lower Oil Ring Side Rail
      *a Front Mark

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

  7. INSTALL CRANKSHAFT BEARING


    1. A01ETCLE01

      Install the upper bearing with an oil groove on the cylinder block.

      Note

      Do not apply engine oil to the backside of the bearing or bearing cap contact surfaces.

  8. INSTALL NO. 2 CRANKSHAFT BEARING


    1. A01EU4YE05
      Text in Illustration
      *a Claw

      Install the No. 2 crankshaft bearing on the bearing cap.

      Note

      Clean the backside of the bearing and the bearing surface of the crankshaft. The surface should be free of dust and oil.

  9. INSTALL UPPER CRANKSHAFT THRUST WASHER


    1. A01EXXVE08
      Text in Illustration
      *a Oil Groove

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

      Note

      Make sure to install the proper thrust washers.

    2. Apply engine oil to the upper crankshaft thrust washers.

  10. INSTALL CRANKSHAFT


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

    2. Apply engine oil to the No.2 crankshaft bearings.

    3. A01EW10E03
      Text in Illustration
      *a Front Mark and Number

      Examine the front marks and install the crankshaft bearing caps on the cylinder block.

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

    5. Install the crankshaft bearing cap set bolts.

      Note

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

    6. Step 1


      1. A01ESR8E02

        Retighten the 10 crankshaft bearing cap set bolts in the sequence shown in the illustration.

        Torque:
        40 N*m  { 408 kgf*cm, 29 ft.*lbf }

    7. Step 2


      1. A01EWS8E13
        Text in Illustration
        *a Paint Mark
        A01ETOA Engine Front

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

      2. Retighten the crankshaft bearing cap set bolts 90° in the numerical order shown in the 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.

  11. INSTALL CONNECTING ROD BEARING


    1. A01ET2PE04
      Text in Illustration
      *a Claw

      Align the bearing claw with the groove on the connecting rod or connecting rod cap.

      Note

      Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oil.

  12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    Note

    The connecting rod cap bolts are tightened in 2 progressive steps.


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

    2. A01EXS0E02
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Oil Ring Side Rail
      *4 Oil Ring Expander
      *5 Lower Oil Ring Side Rail
      *a Front Mark

      Check the position of the piston ring ends.

    3. A01EYEIE02
      Text in Illustration
      *a Front Mark
      A01EUL1 Engine Front

      Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

      Note

      Match the numbered connecting rod cap with the connecting rod.

    4. A01ETE0

      Check that the protrusion on 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. A01EVHG

        Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

    8. Step 2


      1. A01ETHGE23
        Text in Illustration
        *a Paint Mark
        A01ETOA Engine Front

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

      2. Retighten the cap bolts 90° as shown in the illustration.

    9. Check that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance Click here.