CYLINDER BLOCK REASSEMBLY
CAUTION / NOTICE / HINT
Note
Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block sub-
assembly, connecting rod sub-assembly and other parts.
PROCEDURE
1. INSTALL CYLINDER BLOCK STRAIGHT SCREW PLUG
a. Install 2 new gaskets and the 2 cylinder block straight screw plugs.
Torque:
38 N*m { 387 kgf*cm, 28 ft.*lbf }
2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
a. Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. INSTALL PISTON PIN HOLE SNAP RING
a. Using a screwdriver, install a new snap ring on one
side of the piston pin hole.
Text in Illustration
Cutout Position
Tech Tips
Be sure that the end gap of the piston pin hole snap ring is
not aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON WITH PIN SUB-ASSEMBLY
a. Heat the piston to approximately 80°C (176°F).
b. Coat the piston pin with engine oil.
c. RH:
i. Align the front marks of the piston and
connecting rod, and push in the piston pin
with your thumb.
Tech Tips
The piston and piston pin are a matched
set.
The piston has 2 front marks.
Text in Illustration
*a Front Mark
d. LH:
i. Face the front marks of the piston and
connecting rod in opposite directions, and
push in the piston pin with your thumb.
Tech Tips
The piston and piston pin are a matched
set.
The piston has 1 front mark.
e. Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
Text in Illustration
*a Front Mark
5. INSTALL PISTON PIN HOLE SNAP RING
a. Using a screwdriver, install a new piston pin hole
snap ring at the other end of the piston pin hole.
Text in Illustration
Cutout Position
Tech Tips
Be sure that the end gap of the piston pin hole snap ring is
not aligned with the pin hole cutout portion of the piston.
6. INSTALL PISTON RING SET
a. Install the oil ring expander by hand.
b. Using a piston ring expander, install the oil ring.
Text in Illustration
*1 Oil Ring Expander
*2 Oil Ring
*a Coil Joint
*b Oil Ring Ends
Tech Tips
Align the oil ring ends and coil joint as shown in the illustration.
c. Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the
code marks are positioned as shown in the illustration.
Text in Illustration
*1 No. 1 Compression Ring *2 No. 2 Compression Ring
*a Code Mark - -
Tech Tips
Install the No. 1 compression ring with no code mark. The No. 1 compression ring can be installed with either
side facing upward.
Install the No. 2 compression ring with the code mark shown in the table below facing upward.
Standard Code Mark
Code Mark Code Mark
Item (w/ EGR (w/o EGR
System) System)
No. 1 compression
No mark No mark
ring
No. 2 compression
T2 2T
ring
d. Position the piston rings so that the ring ends are as
shown in the illustration.
Text in Illustration
*A for Bank 1
*B for Bank 2
*1 No. 1 Compression Ring
*2 No. 2 Compression Ring
*3 Oil Ring
*4 Oil Ring Expander
*a Front Mark
7. INSTALL CONNECTING ROD BEARING
a. Align the connecting rod bearing claw with the claw
groove of the connecting rod cap.
Note
Clean the contact surface of the connecting rod
bearing and connecting rod cap.
Do not apply engine oil to the connecting rod
bearing and its contact surface.
b. Align the connecting rod bearing claw with the claw
groove of the connecting rod.
Note
Clean the contact surface of the connecting rod
bearing and connecting rod.
Do not apply engine oil to the connecting rod
bearing and its contact surface.
Text in Illustration
*a Claw
8. INSTALL CRANKSHAFT BEARING
Note
Be sure to install the selected crankshaft bearing.
Tech Tips
Main crankshaft bearings come in widths of 20.5 mm (0.807 in.) and 22.5 mm (0.886 in.).
Bearing Width
Item Standard Width
No. 1 and 5 journal bearings 22.5 mm (0.886 in.)
No. 2, 3 and 4 journal bearings 20.5 mm (0.807 in.)
Text in Illustration
*a No. 1 and No. 5 Journal Bearings
*b No. 2, 3 and No. 5 Journal Bearings
*c 22.5 mm (0.886 in.)
*d 20.5 mm (0.807 in.)
a. Clean each main journal and crankshaft bearing.
b. Align the upper crankshaft bearing claw with the
claw groove of the cylinder block sub-assembly, and
push in the 5 upper crankshaft bearings.
Note
Clean the contact surface of the upper crankshaft
bearing and cylinder block sub-assembly.
Do not apply engine oil to the upper crankshaft
bearing and its contact surface.
Both sides of the oil groove in the cylinder block
sub-assembly should be visible through the oil feed
holes in the upper crankshaft bearing. The amount
visible on each side of the holes should be equal.
c. Align the lower crankshaft bearing claw with the
claw groove of the crankshaft bearing cap, and push
in the 5 lower crankshaft bearings.
Note
Clean the contact surface of the lower crankshaft
bearing and crankshaft bearing cap.
Do not apply engine oil to the lower crankshaft
bearing and its contact surface.
Tech Tips
The number marked on each bearing cap indicates the
installation position.
9. INSTALL CRANKSHAFT
Note
Clean the contact surface of each main journal and crank pin.
a. Apply new engine oil to the upper crankshaft bearing and install the crankshaft to the cylinder block sub-
assembly.
b. Push the crankshaft toward the rear thrust direction
to create clearance, and install a crankshaft thrust
washer to the No. 3 journal position with the oil
groove facing the front of the engine.
c. Push the crankshaft toward the forward thrust
direction to create clearance, and install a crankshaft
thrust washer to the No. 3 journal position with the
oil groove facing the rear of the engine.
Text in Illustration
*a Oil Groove
d. Examine the front marks and numbers and install the
crankshaft bearing caps to the cylinder block sub-
assembly.
e. Apply a light coat of engine oil to the threads of the
crankshaft bearing cap bolts.
Text in Illustration
*a Front
f. Temporarily install the crankshaft bearing cap bolts labeled A or the bolts labeled B.
Text in Illustration
*a 8 mm (0.315 in.)
*b Spacer
*c 106 mm (4.17 in.)
*d 90.5 mm (3.56 in.)
*e 11 mm (0.433 in.)
*f 10 mm (0.394 in.)
Tech Tips
In place of the cylinder block stiffening plates, install 8 mm (0.315 in.) thick spacers to the crankshaft bearing cap
bolts.
Standard Length
Item Diameter Length
A 11 mm (0.433 in.) 106 mm (4.17 in.)
B 10 mm (0.394 in.) 90.5 mm (3.56 in.)
g. Uniformly tighten the 2 crankshaft bearing cap bolts for each crankshaft bearing cap in several passes to
ensure a proper fit.
Note
Do not tap the crankshaft bearing cap with a plastic-faced hammer.
h. Remove the crankshaft bearing cap bolts and spacers.
i. Set the 2 cylinder block stiffening plates on the
cylinder block sub-assembly.
Tech Tips
Make sure the arrows on the cylinder block stiffening plates
face the engine front.
Text in Illustration
*a Front Mark
j. Step 1:
Tech Tips
The crankshaft bearing cap bolts are tightened in 4
progressive steps.
If any crankshaft bearing cap bolt is broken or
deformed, replace it.
i. Apply a light coat of engine oil to the threads
and under the heads of the 20 crankshaft
bearing cap bolts A and B.
ii. Install the 20 crankshaft bearing cap bolts.
Using several steps, tighten the bolts
uniformly in the sequence shown in the
illustration.
Torque:
for bolt A
35 N*m { 357 kgf*cm, 26 ft.*lbf }
for bolt B
60 N*m { 612 kgf*cm, 44 ft.*lbf }
k. Step 2:
i. Mark the front side of the crankshaft bearing
cap bolts A and B with paint.
ii. Tighten the crankshaft bearing cap bolts A
and B 90° in the sequence shown in the
illustration.
Text in Illustration
*a Painted Mark
*b Front
l. Step 3:
i. Tighten the crankshaft bearing set cap bolts A
another 90° in the sequence shown in the
illustration.
Text in Illustration
*a Painted Mark
*b Front
m. Check that the painted marks of crankshaft bearing
set cap bolt A are now at a 180° angle to the front.
Text in Illustration
*a Painted Mark
*b Front
n. Check that the painted marks of crankshaft bearing
set cap bolt B are now at a 90° angle to the front.
o. Check that the crankshaft turns smoothly.
Text in Illustration
*a Painted Mark
*b Front
p. Step 4:
i. Using several steps, install the 10 crankshaft
bearing cap set bolts uniformly in the
sequence shown in the illustration.
Torque:
56 N*m { 571 kgf*cm, 41 ft.*lbf }
ii. Check that the crankshaft turns smoothly.
10. INSPECT CRANKSHAFT THRUST CLEARANCE
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11. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
a. Apply engine oil to the cylinder walls, pistons, and
the surfaces of the connecting rod bearings.
b. Check the positions of the piston ring ends.
Text in Illustration
*A for Bank 1
*B for Bank 2
*1 No. 1 Compression Ring
*2 No. 2 Compression Ring
*3 Oil Ring
*4 Oil Ring Expander
*a Front Mark
c. 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.
Text in Illustration
*a RH
*b LH
*c Front Mark
*d Front
d. Install the connecting rod cap so that its protrusion is
facing the correct direction.
Note
Match the numbered connecting rod cap with the
connecting rod.
e. Apply a light coat of engine oil to the threads and
under the heads of the connecting rod cap bolts.
f. Step 1:
Text in Illustration
*a RH
*b LH
*c Front
*d Rear
*e Protrusion
i. Install and alternately tighten the bolts of the
connecting rod cap in several steps.
Torque:
35 N*m { 357 kgf*cm, 26 ft.*lbf }
Tech Tips
The connecting rod cap bolts are tightened
in 2 progressive steps.
If any connecting rod cap bolt is broken or
deformed, replace it.
g. Step 2:
i. Mark the front side of each connecting rod
cap bolt with paint.
ii. Tighten the cap bolts 90°.
Text in Illustration
*a Painted Mark
*b Front
h. Check that the painted marks are now at a 90° angle
to the front.
i. Check that the crankshaft turns smoothly.
Text in Illustration
*a Painted Mark
*b Front
12. INSPECT CONNECTING ROD THRUST CLEARANCE
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