CYLINDER BLOCK REASSEMBLY

Tech Tips

w/ Canister Pump Module:

Perform "Inspection After Repairs" after replacing the piston sub-assembly or piston ring Click here.


  1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL CONNECTING ROD SMALL END BUSH


    1. A01FIERE09
      Text in Illustration
      *1 Oil Hole

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

    2. A01FHKAE08

      Using SST and a press, press in the bush.

      SST
      09222-30010
    3. A01FEIR

      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.

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

  3. INSTALL PISTON SUB-ASSEMBLY WITH PIN

    Tech Tips

    w/ Canister Pump Module:

    Perform "Inspection After Repairs" after replacing the piston Click here.


    1. A01FHYXE06
      Text in Illustration
      *1 Cutout Portion

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

      Tech Tips

      Confirm 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. Coat the piston pin with engine oil.

    4. A01FF4GE06
      Text in Illustration
      *1 Front Mark
      *a Piston RH
      *b Piston LH

      Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      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. A01FJ30E04
      Text in Illustration
      *1 Cutout Portion

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

      Tech Tips

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

  4. INSTALL PISTON RING SET

    Tech Tips

    w/ Canister Pump Module:

    Perform "Inspection After Repairs" after replacing the piston ring Click here.


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

    2. A01FGGVE06
      Text in Illustration
      *1 Oil Ring
      *2 Oil Ring Expander
      *3 Front Mark
      *a Piston RH
      *b Piston LH
      A01FJ4N Engine Front

      Using a piston ring expander, install the oil ring rail as shown in the illustration.

    3. A01FIDWE04
      Text in Illustration
      *1 No. 1 Ring
      *2 No. 2 Ring
      *3 Code Mark

      Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

      Tech Tips


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


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

    4. A01FIUOE06
      Text in Illustration
      *1 No. 1 Ring
      *2 No. 2 Ring
      *3 Front Mark
      *a Piston RH
      *b Piston LH
      A01FJ4N Engine Front

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

      Note

      Do not align the ring ends.

  5. INSTALL CRANKSHAFT BEARING


    1. A01FFGKE15
      Text in Illustration
      *1 No. 1 and No. 4 Journal Bearing
      *2 No. 2 and No. 3 Journal Bearing

      Clean the main journal and both surfaces of the bearings.

      Note

      Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

    2. A01FE4TE08
      Text in Illustration
      *1 Upper Bearing
      *a CORRECT
      *b INCORRECT

      Install the upper crankshaft bearing.


      1. Install the upper crankshaft bearings to the cylinder block as shown in the illustration.

        Note


        • Do not apply engine oil to the bearings and the 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 bearing inner surface.

        • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

    3. A01FF41E03
      Text in Illustration
      *1 Vernier Caliper
      *2 Mark 1, 2, 3, 4 or 5

      Install the lower crankshaft bearing.


      1. Install the lower crankshaft bearings to the crankshaft bearing caps.

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

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

        Note


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

        • Do not allow coolant to come into contact with the bearing inner surface.

        • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

  6. INSTALL CRANKSHAFT THRUST WASHER SET


    1. Apply engine oil to the crankshaft thrust washer.

    2. A01FEKAE03
      Text in Illustration
      *1 Oil Grooves

      Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

  7. INSTALL CRANKSHAFT


    1. Apply engine oil to the upper bearing, and then place the crankshaft on the cylinder block.

    2. A01FI2AE03
      Text in Illustration
      *1 Projection
      *2 Number Mark

      Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block.

      Tech Tips

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

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

    4. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

    5. A01FDIHE06
      Text in Illustration
      *1 Bolt Length
      *a Less than 6 mm (0.236 in.)

      Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide.

      Bolt Length
      100 to 102 mm (3.937 to 4.0157 in.)
    6. A01FHJS

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

    7. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts.

    8. A01FGVKE07
      Text in Illustration
      *1 Bolt Length

      Install the 8 crankshaft bearing cap bolts to the outside positions.

      Bolt Length
      Item Specified Condition
      Bolt A 100 to 102 mm (3.94 to 4.02 in.)
      Except bolt A 105.5 to 107.5 mm (4.15 to 4.23 in.)

    9. Install the crankshaft bearing cap bolts.

      Tech Tips

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

    10. Step 1


      1. A01FHILE06

        Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

        Torque:
        61 N*m  { 622 kgf*cm, 45 ft.*lbf }

        If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it.

    11. Step 2


      1. Mark the front of the bearing cap bolts with paint.

      2. Tighten the cap bolts another 90°.

      3. Check that the painted marks are now at a 90° angle to the front of the engine.

    12. A01FHCQE03

      Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

      Torque:
      26 N*m  { 262 kgf*cm, 19 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt A 45 mm (1.77 in.)
      Except bolt A 30 mm (1.18 in.)

    13. Check that the crankshaft turns smoothly.

    14. Check the crankshaft thrust clearance Click here.

  8. INSTALL CONNECTING ROD BEARING


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

    2. A01FIGXE04
      Text in Illustration
      *1 Vernier Caliper

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

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

      Note

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

  9. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A01FER2E06
      Text in Illustration
      *1 No. 1 Ring
      *2 No. 2 Ring
      *3 Oil Ring
      *4 Oil Ring Expander
      *5 Front Mark
      *a Piston RH
      *b Piston LH
      A01FJ4N Engine Front

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

      Note

      Do not align the ring ends.

    3. A01FFCGE06
      Text in Illustration
      *1 Front Mark
      *a Piston LH
      *b Piston RH
      A01FJ4N Engine Front

      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

      Match the numbered connecting rod cap with the connecting rod.

    4. A01FDUSE06
      Text in Illustration
      *1 Front Mark
      A01FGIV Engine Front

      Check that the front mark of the connecting rod cap is facing forward.

    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.

      Tech Tips

      The cap bolts are tightened in 2 progressive steps.

    7. Step 1


      1. A01FGXT

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

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

      2. Mark the front side of each connecting rod cap bolt with paint.

    8. Step 2


      1. Tighten the cap bolts 90°.

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

    10. Check that the crankshaft turns smoothly.

  10. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01FHHA

      Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.15 to 0.40 mm (0.00591 to 0.0157 in.)
      Maximum thrust clearance
      0.50 mm (0.0197 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.