CYLINDER BLOCK REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL OIL JET

   1. 

      *1	Cylinder Block Sub-assembly
      *a	Upward
      *b	Spool

      Install a new oil jet as shown in the illustration.

      Note:

      Do not tap the tip of the oil jet.

      Tip:

      Press in the oil jet until the spool contacts the cylinder block sub-assembly.

2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

   1. 

      Using a 5 mm socket hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

3. INSTALL OIL CHECK VALVE SUB-ASSEMBLY

   1. 

      Crankshaft Bearing Side

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

      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 WITH PIN SUB-ASSEMBLY

   Note:

   If the piston pin has been removed from the piston, replace the piston, piston pin and connecting rod with new ones.

   1. Gradually heat a new connecting rod to 80 °C (176 °F) or more.

   2. 

      *a	Front Mark

      Coat a new piston pin and pin holes of a new piston with engine oil.

   3. Align the front mark of the piston with that of the connecting rod.

   4. Using SST, press in the piston pin.

      

      *1	Piston Pin	*2	Connecting Rod
      *3	Piston	-	-
      *a	Front Mark	*b	Contact
      	Rear Side	-	-

      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 as 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.

      Tip:

      Perform "Inspection After Repair" after replacing the piston with pin sub-assembly.

      Click here

5. INSTALL PISTON RING SET

   1. 

      *1	Side Rail (Upper)
      *2	Expander Spacer
      *3	Side Rail (Lower)
      *a	Expander Spacer and Side Rail Groove

      Install the expander spacer and 2 side rails by hand, as shown in the illustration.

   2. 

      *1	No. 1 Compression Ring
      *2	No. 2 Compression Ring
      	Upward

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

      Note:

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

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

   3. 

      *1	No. 1 Compression Ring and Side Rail (Upper)
      *2	No. 2 Compression Ring and Side Rail (Lower)
      *3	Expander Spacer
      	Engine Front

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

      Tip:

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

      Click here

6. INSTALL CRANKSHAFT BEARING

   1. Install the 5 upper crankshaft bearings to the cylinder block sub-assembly.

      

      *a	Correct	*b	Incorrect
      	Engine Front	-	-

      Note:

      • Align the oil holes in the crankshaft bearing with the oil holes in the cylinder block sub-assembly.

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

   2. Install the lower crankshaft bearing.

      1. Install the 5 lower crankshaft bearings onto the bearing crankshaft cap.

      2. 

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

         Dimension (A - B)

         0.7 mm (0.0276 in.) or less

         Note:

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

7. INSTALL UPPER CRANKSHAFT THRUST WASHER

   1. 

      *a	Oil Grooves

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

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

8. INSTALL CRANKSHAFT

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

   2. Apply engine oil to the lower crankshaft bearings.

   3. 

      *a	Number Mark
      	Engine Front

      Confirm the number marks and install the crankshaft bearing caps on the cylinder block sub-assembly.

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

   5. 

      Temporarily install the 10 crankshaft bearing cap set bolts.

   6. Step 1

      1. 

         Install and uniformly tighten the 10 crankshaft bearing cap set bolts in the order shown in the illustration.

         30 N*m

         306 kgf*cm

         22 ft.*lbf

   7. Step 2

      1. 

         *a	Paint Mark
         	Engine Front

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

      2. Further tighten the crankshaft bearing cap set bolts an additional 90° in the 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

   1. Install the connecting rod bearing to the connecting rod and connecting rod 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 connecting rod bearings or the contact surfaces.

   3. 

      Using a vernier caliper, measure the distance between the connecting rod 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 connecting rod bearings or the contact surfaces.

10. INSTALL PISTON WITH PIN SUB-ASSEMBLY WITH CONNECTING ROD SUB-ASSEMBLY

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

    2. 

       *1	No. 1 Compression Ring and Side Rail (Upper)
       *2	No. 2 Compression Ring and Side Rail (Lower)
       *3	Expander Spacer
       	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. 

       *a	Front Mark

       Using a piston ring compressor, push the correctly numbered piston with pin sub-assembly with connecting rod into the cylinder block sub-assembly with the front mark of the piston facing forward.

       Note:

       • When inserting the piston with pin sub-assembly with connecting rod, do not allow it to make contact with the No. 1 oil nozzle sub-assembly.

       • Match the numbered connecting rod cap with the connecting rod.

    4. 

       *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 bolts.

    6. Install the connecting rod bolts.

    7. Step 1

       1. 

          Using SST, install and alternately tighten the connecting rod bolts of the connecting rod cap in several steps.

          09205-16010

          15 N*m

          153 kgf*cm

          11 ft.*lbf

    8. Step 2

       1. 

          *a	Paint Mark
          	Engine Front

          Mark the front of the connecting rod bolts with paint.

       2. Further tighten the connecting rod bolts an additional 90° as shown in the illustration.

       3. Check that the paint mark is now at a 90° angle to the front.

    9. Check that the crankshaft turns smoothly.

    10. Check the connecting rod thrust clearance.

        Click here