Cylinder Block Reassembly

Using an E6 "TORX" socket wrench, install the stud bolt labeled A to the cylinder block sub-assembly.

Torque:

for stud bolt A:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Using an E8 "TORX" socket wrench, install the stud bolts labeled B, D and E to the cylinder block sub-assembly.

Torque:

for stud bolt B, D and E:

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

Using an E10 "TORX" socket wrench, install the stud bolt labeled C to the cylinder block sub-assembly.

Torque:

for stud bolt C:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install a new cylinder block water drain cock sub-assembly to the cylinder block sub-assembly.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

HINT:

Install the cylinder block water drain cock sub-assembly so that the installation angle is within the range indicated by the illustration.

Install a new cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

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

Torque:

10 N*m{102 kgf*cm, 9 ft.*lbf}

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

HINT:

1. Be sure that the end gap of the piston pin hole snap ring is not aligned with the service hole cutout portion of the piston.
   
2. If the new piston pin is difficult to insert, heat the piston to approximately 80°C (176°F).
   

   CAUTION:

   Be sure to wear protective gloves.

Coat the piston pin with engine oil.

Align the front marks of the piston and connecting rod sub-assembly, install the connecting rod sub-assembly to the piston and push in the piston pin with your thumb.

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

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

HINT:

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

Install the oil ring expander to the piston by hand.

Using a piston ring expander, install the oil ring rail to the piston.

HINT:

Make sure the end gap of the oil ring rail and the coil joint are on opposite sides.

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring to the piston so that the code marks are positioned as shown in the illustration.

Code Mark:

Item	Code Mark
No. 1 Compression Ring	G1
No. 2 Compression Ring	N2

HINT:

Install the No. 1 compression ring and No. 2 compression ring with the code mark facing upward.

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

NOTICE:

Do not align the ring ends.

Install the No. 1 crankshaft bearing to the cylinder block sub-assembly as shown in the illustration.

Standard width:

4.25 mm (0.167 in.)

NOTICE:

1. Clean the contact surface of the No. 1 crankshaft bearing and cylinder block sub-assembly.
   
2. Apply oil to the inner surface of each No. 1 crankshaft bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the cylinder block sub-assembly).
   

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

NOTICE:

1. Clean the contact surface of the No. 2 crankshaft bearing and crankshaft bearing cap.
   
2. Apply oil to the inner surface of each No. 2 crankshaft bearing (the surface which contacts the crankshaft), but not to the outer surface (the surface which contacts the crankshaft bearing cap).
   

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

Dimension A - B or B - A:

0 to 0.7 mm (0 to 0.0276 in.)

Apply engine oil to the crankshaft bearing, and then install the crankshaft to the cylinder block sub-assembly.

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

HINT:

Check the crankshaft thrust washers, as there are different types as shown in the illustration.

Push the crankshaft in one direction and install one upper crankshaft thrust washer to the No. 5 cylinder block sub-assembly journal position with the oil groove facing outward.

Push the crankshaft in the opposite direction and install the other upper crankshaft thrust washer to the No. 5 cylinder block sub-assembly journal position with the oil groove facing outward.

Install the 2 lower crankshaft thrust washers to the crankshaft bearing cap (No. 5 crankshaft journal) with the grooves facing outward.

Install the 5 crankshaft bearing caps to the cylinder block sub-assembly, making sure that the front marks (protrusions) and crankshaft bearing cap number of the crankshaft bearing caps are as shown in the illustration.

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

Install the crankshaft bearing cap set bolts.

HINT:

1. The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
   
2. If a crankshaft bearing cap set bolt is broken or deformed, replace it.
   

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

Torque:

95 N*m{969 kgf*cm, 70 ft.*lbf}

HINT:

If any of the crankshaft bearing cap set bolts does not meet the torque specification, replace the crankshaft bearing cap set bolt.

Step 2:

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

2. Tighten the crankshaft bearing cap set bolts by 90°.
   

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

Check that the crankshaft turns smoothly.

Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance:

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum thrust clearance:

0.24 mm (0.00945 in.)

Standard crankshaft thrust washer thickness:

2.2 to 2.8 mm (0.0866 to 0.110 in.)

Clean the backside of the connecting rod bearing and the connecting rod bearing surface of the connecting rod sub-assembly and connecting rod cap.

Install the No. 1 connecting rod bearings to the connecting rod sub-assembly.

Install the No. 2 connecting rod bearings to the connecting rod cap.

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

Dimension A - B or B - A:

0 to 0.7 mm (0 to 0.0276 in.)

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

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

NOTICE:

Do not align the piston ring ends.

Using a piston ring compressor and hammer handle, press a piston with connecting rod sub-assembly into each cylinder with the front mark (arrow) of the piston facing forward.

Place the connecting rod cap on the connecting rod sub-assembly.

1. Align the pin holes of the connecting rod cap with the pins of the connecting rod sub-assembly, and then install the connecting rod cap.
   

   Text in Illustration

   *a

   Pin





2. Check that the front mark (protrusion) of the connecting rod cap is facing forward.
   

   Text in Illustration

   *a	Front Mark (Protrusion)
   	Front





3. Check that the matchmarks of the connecting rod sub-assembly and connecting rod cap are aligned.
   

   Text in Illustration

   *a	Front Mark (Protrusion)
   *b	Matchmark

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

Install the connecting rod bolts.

HINT:

The connecting rod bolts are tightened in 2 progressive steps.

1. Step 1:
   Install and alternately tighten the connecting rod 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 bolt with paint.
   

3. Step 2:
   Tighten the connecting rod bolts 90°.
   

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

Check that the crankshaft turns smoothly.

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

Standard thrust clearance:

0.10 to 0.45 mm (0.00394 to 0.0177 in.)

Maximum thrust clearance:

0.45 mm (0.0177 in.)