Cylinder Block Assembly: Service and Repair

NOTE:
- When installing any sliding part (bearings, pistons, etc.), always lubricate contacting surfaces with new engine oil.
- Place removed parts such as bearings and bearing caps in their proper order and direction.

PISTON AND CRANKSHAFT DISASSEMBLY
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove oil pan.
4. Remove timing chain.
5. Remove water pump.
6. Remove cylinder head.
7. Remove pistons with connecting rod.
8. Measure crankshaft end play and remove bearing caps and crankshaft.





NOTE: Bolts should be loosened in two or three steps following the sequence shown.

PISTON ASSEMBLY
1. Heat piston to 60 - 70° C (140 - 158° F) and assemble piston, piston pin and connecting rod.








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





2. Set piston rings as shown.

NOTE:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When piston rings are being replaced and no punchmark is present, piston rings can be mounted with either side up.





3. Align piston rings so that end gaps are positioned as shown.





CRANKSHAFT ASSEMBLY
1. Set main bearings in their proper positions on cylinder block and main bearing beam.

NOTE:
- Confirm that correct main bearings are used.
- Apply new engine oil to bearing surfaces.

Tightening Sequence:

2. Install crankshaft and main bearing beam and tighten bolts to the specified torque.
- Apply new engine oil to the bolt threads and seat surface.
- Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction.
- Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward as shown in figure.
- Torque bearing cap bolts to 46 - 52 Nm (34 - 38 ft. lbs.)
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.





3. Measure crankshaft end play. The standard value is 0.05 - 0.13 mm (0.0020 - 0.0071 inch) and the limit is 0.3 mm (0.012 inch). If beyond the limit, replace bearing with a new one.
4. 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.
- Apply new engine oil to bearing surfaces, bolt threads and seating surfaces.
5. Install pistons with connecting rods.





a. Install them into their corresponding cylinders with piston ring compressor tool No. EM03470000, or equivalent.
- Arrange them so that the front mark on piston head faces toward front of engine.
- Make sure connecting rod does not scratch cylinder wall.
- Make sure connecting rod bolts do not scratch crankshaft journals.
- Apply new engine oil to piston rings and sliding surface of piston.
b. Install connecting rod bearing caps. Tighten connecting rod bearing cap nuts using the following procedure:
- Tighten to 14 - 16 Nm (10 - 12 ft. lbs.).





- Tighten bolts 60 - 65° clockwise with an angle wrench.
- If an angle wrench is not available, tighten them to 38 - 44 Nm (28 - 33 ft. lbs.).





6. Measure connecting rod side clearance. The connecting rod side clearance standard value is 0.2 - 0.4 mm (0.008 - 0.016 inch) and the limit is 0.6 mm (0.024 inch). If beyond the limit, replace connecting rod and/or crankshaft.