CYLINDER BLOCK > REASSEMBLY

for Preparation Click here



1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    A198045

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

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



2. INSTALL PISTON


A198658E03

  1. Gradually heat a new connecting rod to 80°C (176°F) or more.

  1. Coat a new piston pin and pin holes in a new piston with engine oil.

  1. Align the front marks of the piston and connecting rod.
    Text in Illustration 
    *a
    		Front Mark



    A198659E03

  1. Using SST, press in the piston pin.
    Text in Illustration 
    *1
    		Piston Pin
    *2
    		Connecting Rod
    *3
    		Piston
    *a
    		Front Mark

    SST
    09221-25026   (09221-00021, 09221-00030, 09221-00090, 09221-00100, 09221-00150)

    NOTICE:
    1. Press in the piston pin from the side of the piston with the front mark shown in the illustration.
    2. With the connecting rod fully inserted into the piston end, press in the piston pin until it is flush with the piston surface.

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



3. INSTALL PISTON RING SET


    A146333E05

  1. Install the oil ring expander and oil ring by hand.
    Text in Illustration 
    *1
    		Oil Ring
    *2
    		Oil Ring Expander
    *3
    		Coil Joint
    *a
    		Oil Ring Ends

    NOTICE:
    1. Install the expander and oil ring so that their ring ends are at opposite sides.
    2. Securely install the expander to the inner groove of the oil ring.



    A198038E04

  1. Using a piston ring expander, install the No. 1 ring and No. 2 ring as shown in the illustration.
    Text in Illustration 
    *1
    		No. 1 Ring
    *2
    		No. 2 Ring
    *a
    		Upward

    NOTICE:
    1. Install the No. 1 ring with the code mark (1R) facing upward.
    2. Install the No. 2 ring with the code mark (2R) facing upward.



    A198663E03

  1. Position the piston rings so that the ring ends are as shown in the illustration.
    Text in Illustration 
    *1
    		Oil Ring
    *2
    		No. 2 Ring
    *3
    		No. 1 Ring
    *4
    		Oil Ring Expander
    V100135
    		Front



4. INSTALL CRANKSHAFT BEARING


    A198655E03

  1. Install the upper bearing.
    Text in Illustration 
    *a
    		Correct
    *b
    		Incorrect
    V100136
    		Front

    NOTICE:
    1. Align the oil holes on the bearing and cylinder block.
    2. Do not apply engine oil to the bearings or the contact surfaces.



  1. Install the lower bearing.

    1. Install the lower bearing onto the bearing cap.



      2. A198656E01

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

      Dimension (A - B):
      0.7 mm (0.0276 in.) or less

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



5. INSTALL UPPER CRANKSHAFT THRUST WASHER


    A198042E03

  1. Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.
    Text in Illustration 
    *a
    		Oil Grooves

  1. Apply engine oil to the crankshaft thrust washers.



6. INSTALL CRANKSHAFT


A198657E03

  1. Apply engine oil to the upper bearings and install the crankshaft on the cylinder block.
    Text in Illustration 
    *a
    		Number Mark
    V100135
    		Front

  1. Apply engine oil to the lower bearings.

  1. Examine the number marks and install the bearing caps on the cylinder block.

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



    A198039

  1. Temporarily install the 10 main bearing cap bolts.



  1. Step 1



      A198039E02

    1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.

      Torque:
      30 N*m{ 306 kgf*cm , 22 ft.*lbf }



  1. Step 2



      A050671E14

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

    2. Further tighten the bearing cap bolts an additional 90° in the numerical order shown in the previous illustration.
      Text in Illustration 
      *a
      		Paint Mark
      V100136
      		Engine Front

  1. Check that the paint mark is now at a 90° angle to the front.

  1. Check that the crankshaft turns smoothly.

  1. Check the crankshaft thrust clearance (Click here).



7. INSTALL CONNECTING ROD BEARING


A198661

  1. Install the connecting rod bearing to the connecting rod and bearing cap.

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

    Dimension:
    2.2 to 2.6 mm (0.0866 to 0.102 in.)

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



    A198662

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

    Dimension:
    2.2 to 2.6 mm (0.0866 to 0.102 in.)

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



8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


A198663E04

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

  1. Position the piston rings so that the ring ends are as shown in the illustration.
    Text in Illustration 
    *1
    		Oil Ring
    *2
    		No. 2 Ring
    *3
    		No. 1 Ring
    *4
    		Oil Ring Expander
    V100135
    		Front

    NOTICE:
    Do not align the ring ends.



    A198664E03

  1. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
    Text in Illustration 
    *a
    		Front Mark

    NOTICE:
    1. When inserting the piston with connecting rod, do not allow it to make contact with the oil nozzle.
    2. Match the numbered connecting rod cap with the connecting rod.



    A198666E05

  1. Check that the front mark of the connecting rod cap is facing in the correct direction.
    Text in Illustration 
    *a
    		Front Mark

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

  1. Install the connecting rod cap bolts.

    NOTICE:
    The connecting rod cap bolts should be tightened in 2 progressive steps.



  1. Step 1



      A198665E02

    1. Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.

      SST
      09205-16010  

      Torque:
      15 N*m{ 153 kgf*cm , 11 ft.*lbf }



  1. Step 2



      A101478E13

    1. Mark the front of the connecting rod cap bolts with paint.

    2. Further tighten the cap bolts an additional 90° as shown in the illustration.
      Text in Illustration 
      *a
      		Paint Mark
      V100135
      		Engine Front

  1. Check that the crankshaft turns smoothly.

  1. Check the connecting rod thrust clearance (Click here).