CYLINDER BLOCK REASSEMBLY

Tech Tips

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

  1. INSTALL STUD BOLT

    Note

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

    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      A011YV1E01
      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY

    1. Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzles sub-assembly with the 4 bolts.

      A011YK6
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. Using a 5 mm hexagon wrench, install the 2 No. 1 oil nozzles sub-assembly with the 2 bolts.

      A011Y4C
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL PISTON

    1. Using a small screwdriver, install a new snap ring (rear side) at one end of the piston pin hole.

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

    3. Coat the piston, piston pin and connecting rod 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.

      A011YJ2E01
      Text in Illustration
      *a Front Mark

      Tech Tips

      The piston and pin are a matched set.

    5. Using a small screwdriver, install a new snap ring (front side) on the other side of the piston pin hole.

      A011WBGE05
      Text in Illustration
      *1 Snap Ring
      *a Front Mark Cutout Portion

      Tech Tips

      Be sure that the end gap of the snap ring is not aligned with the front mark cutout portion of the piston.

    6. Check the fitting condition between the piston and piston pin.

      A011WXG

      1. Move the connecting rod back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, replace the piston and pin as a set.

      2. Rotate the piston back and forth on the piston pin. Check the fitting condition.

        If abnormal movement is felt, replace the piston and pin as a set.

        Tech Tips

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

  5. INSTALL PISTON RING SET

    1. Install the oil ring expander and oil ring by hand.

      A011Z20E04
      Text in Illustration
      *1 Oil Ring
      *2 Oil Ring Expander
      *3 Coil Joint
      *4 Oil Ring End

      Tech Tips

      Arrange the oil ring ends and coil joint as shown in the illustration.

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

      A011WYXE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Paint Mark
      *b Code Mark
      A011YFS Upward
      Piston Ring Mark
      Item Code Mark Paint Mark
      No. 1 Compression Ring 1N Blue
      No. 2 Compression Ring 2N Orange

      Note

      Install the compression ring with the code mark facing upward.

      Tech Tips

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

  6. INSTALL CRANKSHAFT PULLEY KEY

    1. Install the 2 crankshaft pulley keys to the crankshaft.

  7. INSTALL CRANKSHAFT BEARING

    1. Clean the main journal and both surfaces of the bearing.

      A011Y6YE01
      Text in Illustration
      *a No. 1, No. 5 Journal Bearing
      *b No. 2, No. 4 Journal Bearing
      *c No. 3 Journal Bearing
      *d Silver
      *e Black

    2. Install the upper bearing to the cylinder block as shown in the illustration.

      A011VTVE03
      Text in Illustration
      *a CORRECT
      *b INCORRECT

      Note

      • The color of the No. 3 journal bearing is different from that of the No. 1, No. 2, No. 4 and No. 5 journal bearings. Be sure to check the color before installation.

      • Do not apply engine oil to the bearings or their 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. Install the lower bearing onto the bearing cap.

      A011W6JE02
      Text in Illustration
      *1 Vernier Caliper

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

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

      Note

      • The color of the No. 1 and No. 5 journal bearing is different from that of the No. 2, No. 3 and No. 4 journal bearings. Be sure to check the color before installation.

      • Do not apply engine oil to the 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.

  8. INSTALL CRANKSHAFT THRUST WASHER

    1. Apply engine oil to the thrust washers.

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

      A011Z2JE02
      Text in Illustration
      *1 Oil Groove

  9. INSTALL CRANKSHAFT

    1. Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.

    2. Examine the front marks and numbers, and install the bearing caps onto the cylinder block with the front marks as shown in the illustration.

      A011WJAE01
      Text in Illustration
      *a Front Mark

      Tech Tips

      The crankshaft bearing cap bolts are tightened in 3 progressive steps.

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

    4. Step 1:

      1. Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.

        A011YB9E02
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    5. Step 2:

      1. Tighten the 10 bearing cap bolts again in the sequence shown in the illustration.

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

    6. Step 3:

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

        A011VIXE05
        Text in Illustration
        *a Paint Mark
        A011XJ4 Engine Front

      2. Tighten the 10 bearing cap bolts 90° in the same sequence.

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

    7. Check that the crankshaft turns smoothly.

  10. INSTALL CONNECTING ROD BEARING

    1. Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings.

      A011WBCE02
      Text in Illustration
      *1 Vernier Caliper

    2. Install the connecting rod bearings to the connecting rods and connecting rod caps.

    3. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing cap and connecting rod bearing.

      Standard 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 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.

  11. INSTALL PISTON WITH CONNECTING ROD

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

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

      A011WFTE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *4 Oil Ring (Expander)
      *a Front Mark
      A011YFS Engine Front

    3. Using a hammer handle and piston ring compressor, press a piston with connecting rod into each cylinder with the front mark of the piston facing forward.

      A011W15E01
      Text in Illustration
      *a Front Mark

      Note

      When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod.

      Tech Tips

      The front mark is "2H" printed in raised letters.

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

      A011YXUE02
      Text in Illustration
      *a Front Mark

      Note

      Match the numbered connecting rod cap with the connecting rod.

    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

      A011YSQ

    6. Temporarily install the connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:

      1. Alternately tighten the connecting rod bolts in several steps.

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

    8. Step 2:

      A011VIBE25
      Text in Illustration
      *a Paint Mark
      A011XJ4 Engine Front

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

      2. Tighten the bolts 90° as shown in the illustration.

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

    9. Check that the crankshaft turns smoothly.