REASSEMBLY PROCEDURE 1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
| (a)
Using a 5 mm hexagon socket wrench, install the 3 No. 1 oil nozzle
sub-assemblies to the cylinder block sub-assembly with the 3 bolts. Torque:
9.0 N·m {92 kgf·cm, 80 in·lbf} | |
2. INSTALL PISTON HINT: Perform this procedure only when replacement of the piston pin hole snap ring (rear side) is necessary.
(a) Using a screwdriver, install a new piston pin hole snap ring (rear side) at one end of the piston pin hole.
| (b) Gradually heat the piston to approximately 80°C (176°F). |
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(c) Coat the piston pin with engine oil. CAUTION: Be sure to wear protective gloves.
| (d) Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb.
HINT: The piston and piston pin are a matched set. |
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*A | for Bank 1 | |
*B | for Bank 2 | |
*a | Front Mark | | |
| (e) Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.
NOTICE: Make sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston pin hole. |
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| (f) 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.
HINT: If abnormal movement is felt, replace the piston and piston pin as a set.
(2) Rotate the piston back and forth on the piston pin. Check the fitting condition.
HINT:
- If abnormal movement is felt, replace the piston and piston pin as a set.
- Perform Inspection After Repair after replacing the piston.
Click here 
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3. INSTALL PISTON RING SET (a) Install the oil ring expander and 2 side rails by hand.
| (b) Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.
NOTICE:
- Install the No. 1 compression ring with the code mark (T1) facing upward.
- Install the No. 2 compression ring with the code mark (T2) facing upward.
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*a | No. 1 Compression Ring | |
*b | No. 2 Compression Ring | |
*c | Oil Ring | |
*d | Piston Ring Expander | |
*e | Upper Side Rail | |
*f | Oil Ring Expander | |
*g | Lower Side Rail | |
*h | Code Mark | | |
| (c) Position the piston ring set so that the ring ends are as shown in the illustration.
NOTICE: Do not align the ring ends. HINT: Perform Inspection After Repair after replacing the piston ring.
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*A | for Bank 1 | |
*B | for Bank 2 | |
*a | No. 1 Compression Ring | |
*b | No. 2 Compression Ring | |
*c | Front Mark | |
*d | Lower Side Rail | |
*e | Oil Ring Expander | |
*f | Upper Side Rail | | |
4. INSTALL CRANKSHAFT BEARING
| (a) Clean the main journals and both surfaces of the crankshaft bearings.
NOTICE: Crankshaft
bearings come in widths of 17.9 mm (0.705 in.) and 20.9 mm (0.823 in.).
Install the 20.9 mm (0.823 in.) crankshaft bearings to the No. 1 and
No. 4 cylinder block journal positions. Install the 17.9 mm (0.705 in.)
crankshaft bearings to the No. 2 and No. 3 positions. |
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*a | No. 1 and No. 4 Crankshaft Bearing | |
*b | No. 2 and No. 3 Crankshaft Bearing | |
*c | 20.9 mm | |
*d | 17.9 mm | | |
| (b) Install the upper crankshaft bearings. (1) Install the upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.
NOTICE:
- Do not apply engine oil to the crankshaft bearings or the contact surfaces.
- Both sides of the oil groove in the cylinder block sub-assembly should
be visible through the oil feed holes in the crankshaft bearing. The
amount visible on each side of the holes should be equal.
- Do not allow coolant to come into contact with the crankshaft bearing inner surface.
- If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.
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*a | Upper Crankshaft Bearing | |
*b | Correct | |
*c | Incorrect | | |
| (c) Install the lower crankshaft bearings. (1) Install the lower crankshaft bearings to the crankshaft bearing caps.
(2) Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and lower crankshaft bearing edge.
Difference Between (A) and (B): 0.7 mm (0.0276 in.) or less
NOTICE:
- Do not apply engine oil to the crankshaft bearings or the contact surfaces.
- Do not allow coolant to come into contact with the crankshaft bearing inner surface.
- If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.
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*a | Vernier Caliper | |
*b | Number Mark | | |
5. INSTALL CRANKSHAFT THRUST WASHER SET (a) Apply engine oil to the crankshaft thrust washer set.
| (b)
Install the crankshaft thrust washer set under the No. 2 journal
position of the cylinder block sub-assembly with the oil grooves facing
outward. | |
6. INSTALL CRANKSHAFT (a) Apply engine oil to the crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly.
| (b)
Confirm the projections and numbers of the crankshaft bearing caps and
install the 4 crankshaft bearing caps to the cylinder block
sub-assembly. HINT: A number is marked on each crankshaft bearing cap to indicate its installation position. |
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*a | Projection | |
*b | Number Mark | | |
(c) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.
| (d) Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.
Bolt Length: 100 to 102 mm (3.94 to 4.02 in.) |
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*a | Less than 6 mm | |
*b | Bolt Length | | |
(e)
Push the crankshaft bearing cap with your hand until the clearance
between the crankshaft bearing cap and the cylinder block sub-assembly
is less than 6 mm (0.236 in.) by using the 2 inside crankshaft bearing
cap set bolts as a guide. |
(f) Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit. |
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(g) Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap set bolts.
| (h) Temporarily install the 8 crankshaft bearing cap set bolts to the outside positions.
Bolt Length: 105.5 to 107.5 mm (4.15 to 4.23 in.) | |
(i) Install the crankshaft bearing cap set bolts. HINT: The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
(j) Step 1: | (1) Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
Torque: 61 N·m {622 kgf·cm, 45 ft·lbf} HINT: If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it. |
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(k) Step 2: (1) Mark the front of the crankshaft bearing cap set bolts with paint.
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*a | Paint Mark | |
*b | Turn 90° |
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Front of Engine | (2) Tighten the crankshaft bearing cap set bolts 90° in the order shown in the illustration.
(3) Check that the paint marks are now at a 90° angle to the front.
| (l)
Install 8 new seal washers and uniformly tighten the 8 crankshaft
bearing cap set bolts in several steps in the order shown in the
illustration. Torque: 51.5 N·m {525 kgf·cm, 38 ft·lbf} |
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(m) Check that the crankshaft turns smoothly. (n) Check the crankshaft thrust clearance.
Click here 7. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearings to the connecting rod sub-assembly and connecting rod cap.
| (b)
Using a vernier caliper, measure the distance between the connecting
rod sub-assembly, connecting rod cap edges and the connecting rod
bearing edge. Difference Between (A) and (B): 0.7 mm (0.0276 in.) or less
NOTICE: Do not apply engine oil to the connecting rod bearings or the contact surfaces. |
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8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
| (b) Position the piston ring set so that the ring ends are as shown in the illustration.
NOTICE: Do not align the ring ends. | |
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*A | for Bank 1 | |
*B | for Bank 2 | |
*a | No. 1 Compression Ring | |
*b | No. 2 Compression Ring | |
*c | Front Mark | |
*d | Lower Side Rail | |
*e | Oil Ring Expander | |
*f | Upper Side Rail | | |
(c)
Using a piston ring compressor, push the piston and connecting rod
sub-assembly into the cylinder with the front mark of the piston facing
the front of the engine. 
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*A | for Bank 1 |
*B | for Bank 2 | |
*a | Front Mark |
- | - | |
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Front of Engine | - |
- | NOTICE: Match the connecting rod cap with the connecting rod sub-assembly.
(d) Check that the front mark of the connecting rod cap is facing the front of the engine.
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*a | Front Mark | |
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Front of Engine | (e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
(f) Install the 2 connecting rod bolts. HINT: The connecting rod bolts are tightened in 2 progressive steps.
(g) Step 1: | (1) Alternately tighten the 2 connecting rod bolts in several steps.
Torque: 24.5 N·m {250 kgf·cm, 18 ft·lbf} | |
(h) Step 2: 
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*a | Paint Mark | |
*b | Turn 90° | |
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Front of Engine | (1) Mark the front of each connecting rod bolt with paint.
(2) Further tighten the connecting rod bolts 90° as shown in the illustration.
(3) Check that the paint marks are now at a 90° angle to the front. (i) Confirm that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance. Click here
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