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 THRUST WASHER SET

INSTALL CRANKSHAFT

INSTALL CONNECTING ROD BEARING

INSPECT CRANKSHAFT THRUST CLEARANCE

INSTALL PISTON AND CONNECTING ROD

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

• Torque:
• for stud bolt A:
• 20 N*m{ 199 kgf*cm, 14 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 No. 1 oil nozzles with the 4 bolts.

• Torque:
• 10 N*m{ 102 kgf*cm, 7 ft.*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 service cutout 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, 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.

• 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 by trying to move the piston back and forth on the piston pin.

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 cutout 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.

• HINT:

• Type A and type B can be distinguished by the color of the paint marks or the cross-section shape of the No. 2 compression ring.

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.

Text in Illustration

*1	Oil Groove
*2	Oil Feed Hole
*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 bearings.

Install the lower bearings to the crankshaft bearing caps.

Text in Illustration

*1	Vernier Caliper

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

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

• NOTICE:

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

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.

Apply engine oil to the thrust washer set.

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

Apply new 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 main bearing caps and install the bearing caps to 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 main bearing cap bolts to the inside positions.

Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.236 in.) and partially tighten the 2 inner bearing cap bolts.

• 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 main bearing cap bolts.

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

• Bolt length:
• 79.5 mm (3.13 in.)

Tighten the main bearing cap bolts.

• HINT:

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

Step 1:

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

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

Mark the front of the bearing cap bolts with paint.

Step 2:

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

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 main 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 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:
• 0.020 to 0.220 mm (0.000787 to 0.00866 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:
• 2.44 to 2.49 mm (0.0961 to 0.0980 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.

• NOTICE:

• Do not align the ring ends.

• HINT:

• The expander ends can be placed anywhere.

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.

Place the connecting rod cap on the connecting rod.

Match the numbered connecting rod cap with the connecting rod.

Text in Illustration

*A	for Bank 1
*B	for Bank 2
*1	Front Mark
	Front

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

• Front Mark:

• Item	Front Mark
  LH	Front Side
  RH	Rear Side

Install the connecting rod cap bolts.

• HINT:

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

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.

Step 1:

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

• Torque:
• 40 N*m{ 408 kgf*cm, 30 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.