INSTALL CYLINDER BLOCK STRAIGHT SCREW PLUG

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

INSTALL PISTON PIN HOLE SNAP RING

INSTALL PISTON WITH PIN SUB-ASSEMBLY

INSTALL PISTON PIN HOLE SNAP RING

INSTALL PISTON RING SET

INSTALL CONNECTING ROD BEARING

INSTALL CRANKSHAFT BEARING

INSTALL CRANKSHAFT

INSPECT CRANKSHAFT THRUST CLEARANCE

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

INSPECT CONNECTING ROD THRUST CLEARANCE

Install 2 new gaskets and the 2 straight screw plugs.

• Torque:
• 38 N*m{ 387 kgf*cm, 28 ft.*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 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.

RH:

LH:

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 by hand.

Using a piston ring expander, install the oil ring.

• HINT:

• Align the oil ring ends and coil joint as shown in the illustration.

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

• HINT:

• Standard Code Mark:

• Item	Code Mark (w/ EGR System)	Code Mark (w/o EGR System)
  No. 1 compression ring	No mark	No mark
  No. 2 compression ring	T2	2T

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

Align the bearing claw with the claw groove of the connecting rod cap.

• NOTICE:

Align the bearing claw with the claw groove of the connecting rod.

• NOTICE:

Clean each main journal and bearing.

Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper crankshaft bearings.

• NOTICE:

Align the bearing claw with the claw groove of the bearing cap, and push in the 5 lower crankshaft bearings.

• NOTICE:

• HINT:

• The number marked on each bearing cap indicates the installation position.

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

Push the crankshaft toward the rear thrust direction to create clearance, and install a thrust washer to the No. 3 journal position with the oil groove facing the front of the engine.

Push the crankshaft toward the forward thrust direction to create clearance, and install a thrust washer to the No. 3 journal position with the oil groove facing the rear of the engine.

Examine the front marks and numbers and install the bearing caps to the cylinder block.

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

Temporarily install the crankshaft bearing cap bolts labeled A or the bolts labeled B.

• HINT:

• In place of the cylinder block stiffening plates, install 8 mm (0.315 in.) thick spacers to the crankshaft bearing cap bolts.

Uniformly tighten the 2 crankshaft bearing cap bolts for each bearing cap in several passes to ensure a proper fit.

• NOTICE:

• Do not tap the bearing cap with a plastic-faced hammer.

Remove the crankshaft bearing cap bolts and spacers.

Set the 2 cylinder block stiffening plates on the cylinder block.

• HINT:

• Make sure the arrows on the stiffening plates face the engine front.

Step 1:

• HINT:

Step 2:

Step 3:

Check that the painted marks of bolt A are now at a 180° angle to the front.

Check that the painted marks of bolt B are now at a 90° angle to the front.

Check that the crankshaft turns smoothly.

Step 4:

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

• Standard thrust clearance:
• 0.02 to 0.22 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 the 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 the connecting rod cap so that its protrusion is facing the correct direction.

• NOTICE:

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

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

Step 1:

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

• Torque:
• 35 N*m{ 357 kgf*cm, 26 ft.*lbf}

• HINT:

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

If any connecting rod cap bolt is broken or deformed, replace it.

Step 2:

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

Tighten the cap bolts 90°.

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 thrust clearance while moving the connecting rod back and forth.

• Standard thrust clearance:
• 0.14 to 0.54 mm (0.00551 to 0.0213 in.)

• Maximum thrust clearance:
• 0.60 mm (0.0236 in.)

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

If necessary, replace the crankshaft.