Part 3

CYLINDER BLOCK ASSY (1NZ-FE)(From April, 2004)
OVERHAUL
25. INSPECT CRANKSHAFT OIL CLEARANCE
a. Clean each main journal and bearing.





b. Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap.

NOTICE: Do not apply engine oil to the contact surfaces of the cylinder block and the back side of the bearing.

HINT: Mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap.

Specified clearance:
A - B = within 0.8 mm (0.032 inch)
C - D = within 0.4 mm (0.016 inch)
c. Install the crankshaft onto the cylinder block.





d. Lay a strip of Plastigage across each journal.





e. Check the front marks and numbers and install the bearing caps onto the cylinder block. Apply a light coat of engine oil to the threads of the bearing cap bolts.





g. Using several steps, tighten the bolts with SST in the sequence shown in the illustration.
SST 09011-38121
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)

NOTICE: Do not turn the crankshaft.





h. Mark the front of the bearing cap bolts with paint.
i. Retighten the bearing cap bolts by 90° in the same sequence as step (g).
j. Check that each painted mark is now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.

k. Remove the bearing cap sub-assembly.





l. Measure the Plastigage at its widest point.
Standard oil clearance: 0.01 to 0.023 mm (0.0004 to 0.0009 inch)
Maximum oil clearance: 0.07 mm (0.0028 inch)

NOTICE: Completely remove the Plastigage.

NOTICE: Completely remove the Plastigage.











HINT:
^ If the width is greater than maximum, select and replace the bearing. If necessary, use the undersize bearing.
^ To select the correct bearing size, calculate the bearing number by adding together the numbers imprinted on the cylinder block and crank journal.
^ Example:

Imprinted number on the cylinder block is 3.
Imprinted number on the crank journal is 5.
3 + 5 = 8
Select the bearing with the bearing number 3.

26. INSTALL CYLINDER BLOCK WATER DRAIN COCK PLUG
a. Apply 2 or 3 threads of adhesive to the drain union, and install it within 3 minutes of applying.





b. After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)

NOTICE:
^ Install the water drain cock within 3 minutes of applying adhesive.
^ Do not put in coolant for at least 1 hour after installation.
^ Do not rotate the drain union more than 360° in step (b), and never loosen it after setting the union correctly.
^ The pipe of the drain cock should be within 40° of the vertical.

27. INSTALL TIGHT PLUG
a. Apply adhesive to the tight plugs.








b. Using SST, tap in the new tight plugs as shown in the illustration.
SST 09950-60010 (09951-00180), 09950-70010 (09951-07100)
Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 inch)





28. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap in the new straight pin.
Standard protrusion: 8.5 to 9.5 mm (0.335 to 0.374 inch)
29. INSTALL STRAIGHT PIN





a. Using a plastic-faced hammer, tap in the new straight pin.
Standard protrusion:
Pin A 3.5 to 4.5 mm (0.138 to 0.177 inch)
Pin B 18.5 to 19.5 mm (0.728 to 0.768 inch)
Pin C 8.5 to 9.5 mm (0.335 to 0.374 inch)
Pin D 11.5 to 12.5 mm (0.453 to 0.492 inch)
30. INSTALL STUD BOLT





a. Using Torx socket wrench E5, install the 6 stud bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)





31. INSTALL CRANKSHAFT
a. Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap.

NOTICE: Do not apply engine oil to the contact surface of the cylinder block or the back side of the bearing.

HINT: Mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap.

Specified clearance:
A - B = within 0.8 mm (0.032 inch)
C - D = within 0.4 mm (0.016 inch)





b. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
c. Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.





d. Check the front marks and numbers and install the bearing caps onto the cylinder block.
e. Apply a light coat of engine oil to the threads of the bearing cap bolts.





f. Using several steps, tighten the bolts with SST in the sequence shown in the illustration.
SST 09011-38121
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)

NOTICE: Check that the crankshaft turns smoothly.





g. Mark the front of the bearing cap bolts with paint.
h. Retighten the bearing cap bolts by 90° in the same sequence as step (g).
i. Check that each painted mark is now at a 90° angle to the front.





32. INSTALL W/ PIN PISTON SUB-ASSY
a. Coat the inner surface of the connecting rod bore and piston pin with engine oil.
b. Align the cavity of the piston with the protruding portion of the connecting rod.





c. Using SST, push in the piston pin.
SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150)

NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so they can be returned to the original locations when reassembling.





33. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the grooves of the connecting rod and connecting cap.

NOTICE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oils.





34. INSTALL PISTON RING SET

HINT: If reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.

a. Install the oil ring expander and 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings.





c. Position the piston rings so that the ring ends are as shown.
35. INSTALL PISTON SUB-ASSY W/ CONNECTING ROD
a. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
b. Check the position of the piston ring ends.





c. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTICE:
^ Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oils.
^ Match the numbered connecting rod cap with the correct connecting rod.





d. Match together the connecting rod and cap in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented.
e. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.





f. Using SST, tighten the bolts in several steps to the specified torque.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)





g. Mark the front of the connecting cap bolts with paint.
h. Retighten the cap bolts by 90° as shown.
i. Check that each painted mark is at a 90° angle to the front.
j. Check that the crankshaft turns smoothly.
SST 09205-16010