Cylinder Block Assembly: Service and Repair

- When installing bearings, pistons, or other sliding parts, lubricate contacting surfaces with new engine oil.
- Place removed parts such as bearings and bearing caps in their proper order and direction.
- When installing connecting rod nuts, and main bearing cap bolts, apply new engine oil to threads and seating surfaces.
- Do not allow any magnetic materials to contact the signal plate teeth of drive plate.





DISASSEMBLY
1. Place engine on a work stand.
2. Remove timing belt.
3. Drain coolant and remove water pump.
4. Drain oil.
5. Remove oil pan, oil pump and rear oil seal retainer.
6. Remove intake manifold collector, intake manifold and cylinder head.





7. Remove pistons.
- When disassembling piston and connecting rod, remove snap ring first. Then heat piston to 60 - 70° C (140 - 158° F), or use piston pin press stand at room temperature.





8. Remove bearing cap and crankshaft.

NOTE:
- Before removing bearing cap, measure crankshaft end play.
- Bolts should be loosened in two or three steps.








ASSEMBLY
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 - 70° C (140 - 158° F) and assemble piston, piston pin, connecting rod and new snap ring.





- Align the direction of piston and connecting rod.
- Numbers stamped on connecting rod and cap correspond to each cylinder.
- After assembly, make sure connecting rod swings smoothly.





3. Set piston rings as shown.

NOTE:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When replacing piston rings, these without punchmarks, present, piston rings can be mounted with either side up.





- Align piston rings so that end gaps are positioned as shown in the figure.





4. Set main bearings in their proper positions on cylinder block and main bearing cap.
- Confirm that correct main bearings are used.
- Apply engine oil to bearing surfaces.
5. Install crankshaft and main bearing caps and tighten bolts to the specified torque.
- Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing cap.





- Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially.
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
- Lubricate threads and seat surfaces of the bolts with new engine oil.





6. Measure crankshaft end play.

Standard: 0.05 - 0.18 mm (0.0020 - 0.0071 inch)
Limit: 0.30 mm (0.0118 inch)

If beyond the limit, replace bearing with a new one.
7. Install connecting rod bearings in connecting rods and connecting rod caps.
- Confirm that correct bearings are used.





- Install bearings so that oil hole in connecting rod aligns with oil hole of bearing.
8. Install pistons with connecting rods.





a. Install them into corresponding cylinders with tool.

NOTE:
- Be careful not to scratch cylinder wall by connecting rod.
- Arrange so that front mark on piston head faces toward front of engine.
- Apply new engine oil to bolt threads and bearing surfaces.





b. Install connecting rod bearing caps.
- Lubricate threads and seat surfaces with new engine oil. Tighten connecting rod bearing cap nuts to 14 - 16 Nm (10 - 12 ft. lbs.). Then, tighten to 59 - 65 Nm (43 - 48 ft. lbs.) or if you have an angle wrench, tighten bolts 60 - 65° clockwise.





9. Measure connecting rod side clearance. Connecting rod side clearance:

Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit: 0.40 mm (0.0157 inch)

If beyond the limit, replace connecting rod and/or crankshaft.