Cylinder Block Assembly: Service and Repair

PISTON AND CRANKSHAFT DISASSEMBLY
1. Remove timing chain.





2. Remove pistons with connecting rods. When disassembling piston and connecting rod, remove snap ring first. Then heat piston to 60 - 70° C (140 - 158° F), or use a piston pin press at room temperature.
3. Remove rear oil seal retainer.

NOTE:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When replacing piston rings, if there is no punchmark, install with either side up.





4. Measure crankshaft end play, and in the order shown, remove bearing cap bolts and then the crankshaft.

NOTE: Bolts should be loosened in two or three steps.

PISTON 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.





3. Align the direction of piston and connecting rod. The numbers stamped on the connecting rod and cap correspond to each cylinder.

NOTE: After assembly, make sure connecting rod swings smoothly.





4. 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.





CRANKSHAFT ASSEMBLY
1. Set main bearings in their proper positions on cylinder block and main bearing cap. Ensure that the correct main bearings are used. Apply engine oil to bearing surface.





2. Install crankshaft, main bearing caps and bearing bolts. Tighten to the specified torque. Lubricate threads and seat surfaces of the bolts with new engine oil. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting in the axial direction. Tighten as follows:
a. In the order shown, tighten bolt Nos. 1 - 10 to 36 - 42 Nm (27 - 31 ft. lbs.) and bolt Nos. 11 - 20 to 26 - 32 Nm (20 - 24 ft. lbs.).
b. Using as angle wrench, turn bolt Nos. 1 through 10 to 35 - 45° clockwise and bolt Nos. 11 through 20, 30 - 40° clockwise, as shown.
c. Tighten bolt Nos. 21 - 30 to 46 - 52 Nm (34 - 38 ft. lbs.), as shown.

NOTE: After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.





3. Measure crankshaft end play. The standard end play is 0.10 - 0.26 mm (0.0039 - 0.0102 inch) and the limit is 0.30 mm (0.0118 inch). If beyond the limit, replace bearing with a new one.





4. Install connecting rod bearings in connecting rods and connecting rod caps. Ensure that correct bearings are used. Install bearings so that oil hole in connecting rod aligns with oil hole of bearing.
5. Install pistons with connecting rods.





a. Install them into corresponding cylinders with tool. Be careful not to scratch cylinder wall with the connecting rod. Arrange them so that front mark on piston head faces toward front of engine. Apply engine oil to piston rings and sliding surface of piston.





b. Install connecting rod caps.
c. Apply engine oil to bolt threads and bearing surface. Tighten connecting rod bearing cap nuts to 14 - 16 Nm (10 - 12 ft. lbs.) then turn the nuts 60 - 65° clockwise with angle wrench.





6. Measure connecting rod side clearance. The standard value is 0.20 - 0.35 mm (0.0079 - 0.0138 inch) and the limit is 0.40 mm (0.0157 inch). If beyond the limit, replace connecting rod and/or crankshaft.
7. Install rear oil seal retainer.