INSTALL STUD BOLT

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

INSTALL PISTON WITH PIN SUB-ASSEMBLY

INSTALL PISTON RING SET

INSTALL CRANKSHAFT BEARING

INSTALL CRANKSHAFT

INSTALL CONNECTING ROD BEARING

INSPECT CRANKSHAFT THRUST CLEARANCE

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

INSPECT CONNECTING ROD THRUST CLEARANCE

Install new stud bolts.

• Torque:
• for stud bolt A and C:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
• for stud bolt B and D:
• 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}

Using a 5 mm hexagon socket wrench, install the 3 oil nozzles with the 3 bolts.

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

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

• HINT:

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

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

Coat the piston pin with engine oil.

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.

• HINT:

• The piston and pin are a matched set.

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 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 pin hole cutout portion of the piston.

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

Using a piston ring expander, install the 2 compression rings with the painted mark on the right side.

Text in Illustration

*1	Painted Mark
*2	No. 1 Compression Ring
*3	No. 2 Compression Ring
	Right Side

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

Clean each main journal and bearing.

Install the upper bearing.

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

Text in Illustration

*a	CORRECT
*b	INCORRECT

• NOTICE:

Do not apply engine oil to the bearings or 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 inner surface of the bearing.

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

Install the lower bearing.

Apply new engine oil to the upper bearing and install the crankshaft to the cylinder block.

Push the crankshaft in the rear thrust direction to create clearance and install a thrust washer to the No. 2 journal position with the oil groove facing the front of the engine.

Push the crankshaft in the forward thrust direction to create clearance and install a thrust washer to the No. 2 journal position with the oil groove facing the rear of the engine.

Install the 2 lower thrust washers to the No. 2 bearing cap with the grooves facing outward.

Examine the front marks and numbers and set the crankshaft bearing caps on the cylinder block.

Apply a light coat of engine oil to the threads of the crankshaft bearing cap bolts.

Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

Tighten the 2 bolts for each bearing cap until the clearance between the crankshaft bearing cap and the cylinder block becomes less than 6 mm (0.236 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 of the crankshaft bearing cap bolts and temporarily install the 8 crankshaft bearing bolts to the outside positions.

Tighten the crankshaft bearing cap bolts.

• HINT:

• The cap bolts are tightened in 2 progressive steps.

Step 1:

Uniformly tighten the 16 bolts in several steps in the order shown in the illustration.

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

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

Step 2:

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

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

Check that the crankshaft turns smoothly.

Install and uniformly tighten the 8 main bearing cap bolts together with 8 new seal washers in several steps in the sequence shown in the illustration.

• Torque:
• 26 N*m{ 262 kgf*cm, 19 ft.*lbf}

• Standard Bolt:

• Item	Length
  Bolt A	45 mm (1.77 in.)
  Bolt B	30 mm (1.18 in.)

Text in Illustration

	Bolt A
	Bolt B

Check that the crankshaft turns smoothly.

Install the bearing to the connecting rod cap.

• NOTICE:

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.)

Install the bearing to the connecting rod.

• NOTICE:

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

• Dimension A - B or B - A:
• 0 to 0.7 mm (0 to 0.0276 in.)

Using a dial indicator, measure the 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:
• 0.30 mm (0.0118 in.)

If the thrust clearance is more than the maximum, replace the thrust washers as a set.

• Standard thrust washer thickness:
• 1.93 to 1.98 mm (0.0760 to 0.0780 in.)

If necessary, replace the crankshaft.

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

Check the positions of the piston ring ends.

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

Install each connecting rod cap so that the protrusion is facing the correct direction.

Text in Illustration

*1	Protrusion
	Front

• NOTICE:

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

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

Install the connecting rod cap bolts.

• HINT:

• The cap bolts are tightened in 2 progressive steps.

Step 1:

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

• Torque:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

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

Step 2:

Tighten the cap bolts 90°.

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 back and forth.

• Standard thrust clearance:
• 0.15 to 0.30 mm (0.00591 to 0.0118 in.)

• Maximum thrust clearance:
• 0.35 mm (0.0138 in.)

If the thrust clearance is more than the maximum, replace one or more connecting rods as necessary.

• Standard connecting rod thickness:
• 20.80 to 20.85 mm (0.819 to 0.821 in.)

If necessary, replace the crankshaft.