CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the piston or piston ring.


PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. Using E6 and E8 "TORX" socket wrenches, install the 4 stud bolts.

      B007ZMCC02
      *a Front Side *b LH Side
      *c RH Side *d 9 mm (0.354 in.)
      *e 12 mm (0.472 in.) *f 16 mm (0.630 in.)
      *g 21 mm (0.827 in.) *h 24 mm (0.945 in.)
      *i 34 mm (1.34 in.) *j 52 mm (2.05 in.)
      Torque:
      Stud Bolt (A)
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      Stud Bolt (B), (C)
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL OIL PIPE SUB-ASSEMBLY


    1. Install a new oil pipe gasket to the oil pipe sub-assembly.

    2. B007ZOFC04
      B007WXX Hexagon Socket Head Cap Bolt
      B00803L Bolt

      Temporarily install the oil pipe sub-assembly.


      1. Temporarily install the 3 bolts in the order shown in the illustration.

      2. Using a 5 mm hexagon socket wrench, temporarily install the 4 hexagon socket head cap bolts in the order shown in the illustration.

    3. B007ZOFC05
      B007WXX Hexagon Socket Head Cap Bolt
      B00803L Bolt

      Tighten the oil pipe sub-assembly.


      1. Using a 5 mm hexagon socket wrench, tighten the 4 hexagon socket head cap bolts in the order shown in the illustration.

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

      2. Tighten the 3 bolts in the order shown in the illustration.

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

  3. INSTALL PISTON

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston.

    Click here


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

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

    3. Coat the piston, piston pin and connecting rod with engine oil.

    4. B007Z1WC03
      *a Cutout
      *b Front Mark

      Align the cutout of the piston and front mark of the connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the piston pin hole snap ring.

      Tech Tips

      The piston and piston pin are a matched set.

    5. B007X8OC15
      *1 Piston Pin Hole Snap Ring
      *a Cutout

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

      Tech Tips

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

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


      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 piston 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 piston pin as a set.

  4. INSTALL PISTON RING SET

    Tech Tips

    Perform "Inspection After Repairs" after replacing the piston ring set.

    Click here


    1. B007YXDC10
      *1 Upper Side Rail
      *2 Oil Ring Expander
      *3 Lower Side Rail

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

    2. B007YA6C02
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *a Paint Mark
      *b Code Mark (2T)
      B007WXX Upward

      Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown in the illustration.

      Piston Ring Mark
      Item Code Mark Paint Mark
      No. 1 Compression Ring - Yellowish Green
      No. 2 Compression Ring 2T Blue

      Note

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

    3. B007YXVC02
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Side Rail
      *4 Lower Side Rail
      *5 Oil Ring Expander
      *a Front Mark
      B007WXX Front of Engine

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

      Tech Tips

      The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

  5. INSTALL CRANKSHAFT PULLEY SET KEY


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

  6. INSTALL CRANKSHAFT BEARING


    1. B007X2DC02
      *a Correct
      *b Incorrect

      Clean the main journal and both surfaces of the crankshaft bearings and No. 2 crankshaft bearings.

    2. Install the crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

      Note


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

      • Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.

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

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

      Tech Tips

      The colors of the crankshaft bearing and No. 2 crankshaft bearing differ depending on the installation position.

      Journal Position Crankshaft Bearing No. 2 Crankshaft Bearing
      No. 1 Black Black
      No. 2 Silver Silver
      No. 3 Black Silver
      No. 4 Silver Silver
      No. 5 Silver Black
    3. B007X44C02
      *a Vernier Caliper

      Install the No. 2 crankshaft bearings to the crankshaft bearing caps.

    4. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the No. 2 crankshaft bearing edge.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


      • Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.

      • Do not allow coolant to come into contact with the No. 2 crankshaft bearing inner surface.

      • If any coolant comes into contact with the No. 2 crankshaft bearing inner surface, replace the No. 2 crankshaft bearing with a new one.

  7. INSTALL CRANKSHAFT THRUST WASHER


    1. B007ZDZC02
      *a Oil Groove

      Apply engine oil to the 2 crankshaft thrust washers.

    2. Install the 2 crankshaft thrust washers to the No. 3 journal of the cylinder block sub-assembly with the oil grooves facing outward.

  8. INSTALL CRANKSHAFT


    1. B007X55C02
      *a Front Mark

      Apply engine oil to the crankshaft bearings, and place the crankshaft on the cylinder block sub-assembly.

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

    3. Confirm the front marks and numbers, and install the 5 crankshaft bearing caps onto the cylinder block sub-assembly with the front marks positioned as shown in the illustration.

      Tech Tips

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

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

    5. Step 1:


      1. B007ZCZN04

        Uniformly install and tighten the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.

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

    6. Step 2:


      1. Further tighten the 10 crankshaft bearing cap bolts in the order shown in the illustration.

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

        If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

    7. Step 3:


      1. B007XZMC14
        *a Paint Mark
        *b 90°
        B00803L Front of Engine

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

      2. Tighten the 10 crankshaft bearing cap bolts 90° in the order shown in step 1.

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

    8. Check that the crankshaft turns smoothly.

  9. INSTALL CONNECTING ROD BEARING


    1. B007Z9MC03
      *a Vernier Caliper

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

    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 connecting rod cap and connecting rod bearing.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

      Note


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

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

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

  10. INSTALL PISTON WITH CONNECTING ROD


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

    2. B007YXVC02
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Upper Side Rail
      *4 Lower Side Rail
      *5 Oil Ring Expander
      *a Front Mark
      B007WXX Front of Engine

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

      Tech Tips

      The oil ring expander can be installed with the ring ends in either of the directions shown in the illustration.

    3. B007Y2FC02
      *a Front Mark

      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 the front of the engine.

      Note

      When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the oil pipe sub-assembly does not interfere with the connecting rod.

    4. B007YU5C02
      *a Front Mark

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

      Note

      Match the 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.

    6. Temporarily install the 2 connecting rod bolts.

      Tech Tips

      The connecting rod bolts are tightened in 2 progressive steps.

    7. Step 1:


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

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

      2. Mark the front of the 2 connecting rod bolts with paint.

    8. B007YCUC70
      *a Paint Mark
      *b 90°
      B00803L Front of Engine

      Step 2:


      1. Tighten the connecting rod bolts 90° as shown in the illustration.

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

    9. Check that the crankshaft turns smoothly.