Cylinder Block Reassembly

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

Torque:

for stud bolt A:

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

for stud bolt B:

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

Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.

Torque:

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

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

HINT:

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

Gradually heat the piston to approximately 80°C (176°F).

Coat the piston pin and connecting rod with engine oil.

Align the front marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the snap ring.

NOTICE:

For the LH side, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For the RH side, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides.

HINT:

The piston and pin are a matched set.

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 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.
   

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

HINT:

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

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

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

Paint Mark:

Item	Paint Mark
No. 1 compression ring	Yellow
No. 2 compression ring	Green

Text in Illustration

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*3	Paint Mark
	Top

Clean the main journal and both surfaces of the bearing.

Install the upper bearing.

NOTICE:

Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.

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

   Text in Illustration

   *a	CORRECT
   *b	INCORRECT

   NOTICE:

   1. Do not apply engine oil to the bearings and the contact surfaces.
      
   2. 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.
      
   3. Do not allow coolant to come into contact with the bearing inner surface.
      
   4. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
      

Install the lower bearing.

NOTICE:

1. Be sure to install the selected bearing.
   
2. Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions.
   

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

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

   Dimension A - B or B - A:

   0 to 0.7 mm (0 to 0.0276 in.)
   

   Text in Illustration

   *1	Vernier Caliper

   NOTICE:

   1. Do not apply engine oil to the bearings and the contact surfaces.
      
   2. Do not allow coolant to come into contact with the bearing inner surface.
      
   3. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
      

Apply engine oil to the thrust washer set.

Install the 4 thrust washers to the No. 3 journal position of the cylinder block and crankshaft bearing cap with the oil grooves facing outward.

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

Confirm the front marks and numbers of the crankshaft bearing caps, and install the crankshaft bearing caps on the cylinder block.

HINT:

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

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

Temporarily install the 10 crankshaft bearing cap bolts to the inside positions.

Push the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block is less than 6 mm (0.236 in.).

Bolt length:

91 mm (3.58 in.)

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

Apply a light coat of engine oil to the threads and under the heads of the 10 crankshaft bearing cap bolts.

Temporarily install the 10 crankshaft bearing cap bolts to the outside positions.

Bolt length:

79.5 mm (3.13 in.)

HINT:

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

Step 1:

1. Uniformly tighten the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.
   

   Torque:

   for inside position:

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

   for outside position:

   27 N*m{275 kgf*cm, 20 ft.*lbf}

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

Step 2:

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

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

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

Check that the crankshaft turns smoothly.

Install and uniformly tighten the 10 crankshaft bearing cap bolts and 10 new seal washers in several steps in the sequence shown in the illustration.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Check that the crankshaft turns smoothly.

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

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

Dimension A - B or B - A:

0 to 0.7 mm (0 to 0.0276 in.)

NOTICE:

1. Do not apply engine oil to the bearings and the contact surfaces.
   
2. Do not allow coolant to come into contact with the bearing inner surface.
   
3. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
   

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

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

NOTICE:

Do not align the ring ends.

HINT:

The expander ends can be placed anywhere.

Using a hammer handle and piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward.

Place the connecting rod cap on the connecting rod.

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

2. Place the connecting rod cap on the connecting rod, and check that the front mark of the connecting rod cap is facing the direction indicated in the chart below.
   

   Front Mark:

   Item	Front Mark
   Bank 1	Front side
   Bank 2	Rear side

   Text in Illustration

   *1	Front Mark
   	Front

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

Temporarily install the connecting rod cap bolts.

HINT:

The connecting rod cap bolts are tightened in 2 progressive steps.

Step 1:

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

   Torque:

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

Step 2:

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

2. Tighten the cap bolts 90° as shown in the illustration in the order in step 1.
   

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

Check that the crankshaft turns smoothly.