Cylinder Block Assembly (I)
CYLINDER BLOCK ASSEMBLY (I)1. Assemble in the order indicated in the table.
Thrust Bearing And Main Bearing Assembly Note
CAUTION:
- If the thrust bearings and main bearings are reused, assemble the bearings to the same positions and in the direction as before removal to prevent engine damage due to seizure or burning of the bearing.
- To prevent engine damage due to seizure or burning of the bearing, apply engine oil to the sliding part when assembling.
Plate Assembly Note
CAUTION: Placing the crankshaft on a disassembly bench will deform or damage it because the plate for the crankshaft position sensor signal detection installed to the crankshaft is larger than the counterweight. Therefore, set wood blocks or similar objects on the both sides of the crankshaft so that the plate does not contact the disassembly bench directly when placing the crankshaft on it bench.
1. Install the plate using the following procedure:
1. Install the groove of the plate tooth to the position shown in the figure and temporarily tighten bolt A.
2. Temporarily tighten the bolt B.
3. Install bolt C and tighten the bolts to the specified tightening torque in the order of C, B, and A.
Tightening torque 20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf}
Lower Cylinder Block Assembly Note
1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the lower cylinder block and cylinder block.
2. When reusing the lower cylinder block installation bolts, clean any old sealant from the bolts.
CAUTION:
- Apply silicon sealant in a single, unbroken line.
- To prevent silicon sealant from hardening, adhere the engine front cover and the cylinder block firmly within 10 min. after applying silicon sealant. After adhering them, tighten the installation bolts immediately.
- Using bolts with the old seal adhering could cause cracks in the cylinder block, etc.
3. Apply silicon sealant to the lower cylinder block shown in the figure.
Bead thickness
A: 3-7 mm {0.12-0.27 in}
B: 2-6 mm {0.1-0.2 in}
4. Install the lower cylinder block.
5. Tighten the lower cylinder block installation bolts using the following procedure:
1. Apply clean engine oil to seating surface and thread of the lower cylinder block installation bolts A.
2 Tighten the lower cylinder block installation bolts A in the order shown in the figure using the following procedure:
Tightening procedure
1. 38-42 N.m {3.9-4.2 kgf.m, 29-30 ft.lbf}
2. Loosen all the bolts (until bolts are torque-free).
3. 24-28 N.m {2.5-2.8 kgf.m, 18-20 ft.lbf}
4. 57.5-62.5°
3. Tighten the lower cylinder block installation bolts B in the order shown in the figure.
Tightening torque 19-25 N.m {2.0-2.5 kgf.m, 15-18 ft.lbf}
6. After verifying that silicone sealant protrudes to the rear oil seal press-in part, wipe away the excess silicone sealant.
- If silicone sealant does not protrude to the rear oil seal press-in part, remove the lower cylinder block and apply silicone sealant again.
Piston Pin Assembly Note
1. Apply clean engine oil to the piston pin.
2. Insert the piston pin to the piston and connecting rod.
NOTE: When assembling the piston to the connecting rod, each one can be assembled in either direction.
Snap Ring Assembly Note
CAUTION: Do not compress the outer diameter of the snap ring more than necessary when assembling the snap ring (reference: 20.66 mm {0.8134 in} or less).
1. Insert a new snap ring using a thin plier.
Piston Ring Assembly Note
NOTE: It is not required to position the end gap between the top ring and second ring.
1. Assemble the piston ring so that the end gap of each oil ring does not overlap as shown in the figure.
2. Install the second ring with the notch facing downward.
3. Install the top ring with the notch facing upward.
Connecting Rod Bearing Assembly Note
CAUTION:
- If a connecting rod bearing is reused, assemble it to the same position and in the direction as before removal to prevent engine damage due to seizure or burning of the bearing.
- To prevent engine damage due to seizure or burning of the bearing, apply engine oil to the sliding part when assembling.
Piston, Connecting Rod Assembly Note
1. Insert the piston into the cylinder with the mark on top of the piston facing the intake side.
Connecting Rod Cap Assembly Note
CAUTION:
- When assembling the connecting rod caps, align the broken, rough faces of the connecting rods and connecting rod caps.
- If the following condition is met, replace the connecting rod cap bolts.
- Length exceeds maximum specification
Standard connecting rod cap bolt length 43.7-44.3 mm {1.73-1.74 in}
Maximum connecting rod cap bolt length 45.0 mm {1.77 in}
1. Position so that the broken, rough faces of the connecting rods and connecting rod caps are aligned exactly, and assemble the connecting rod caps.
2. Tighten the connecting rod cap bolts in the following two steps.
Tightening procedure
Step 1: 26-32 N.m {2.7-3.2 kgf.m, 20-23 ft.lbf}
Step 2: 80-100°
Pilot Bearing Assembly Note
1. Install new pilot bearing to the specified position using the following tools.
Tool
Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20-22 mm {0.79-0.86 in})
- Use the adapter with the 20 mm {0.79 in} side of the A160M7 (20-22 mm {0.79 -0.86 in}) facing the pilot bearing side.
Substitution tool
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
Standard pilot bearing position
Distance A of pilot bearing from crankshaft end: 1.5-2.5 mm {0.060-0.098 in}