RM38T0EC _51 Engine / Hybrid System _144958 M20F-FXS, M20G-FXS ENGINE MECHANICAL _0604256 CYLINDER BLOCK A

M20F-FXS, M20G-FXS ENGINE MECHANICAL  CYLINDER BLOCK  REASSEMBLY  


CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)
A528929N01
5.75,0.885 6.583,2.135 0.833,1.25 5.5,2.167 6.333,3.667 0.833,1.5 5.417,3.802 5.917,4.302 0.5,0.5 1.917,5.417 2.333,5.583 0.417,0.167 1.875,5.375 2.375,5.625 0.5,0.25 4.583,4.917 5,5.083 0.417,0.167 4.542,4.875 5.042,5.125 0.5,0.25 0.542,4.333 1.208,4.5 0.667,0.167 1,0.25 1.75,0.417 0.75,0.167 2.333,5.5 2.667,5.5 false 5,5 5.333,5 false 5.781,4.583 6.198,4.583 false 5.917,4.083 6.25,4.083 false 5.417,3 5.5,3 false 6.583,2.833 6.583,3.25 false 6.438,2.646 6.438,2.479 6.438,2.479 6.938,2.479 false 6.885,2.479 6.885,2.896 false 5.583,1.333 5.75,1.333 false 4.833,1.917 4.833,2.167 false 4.021,2.688 4.354,2.688 false 3.667,2.813 3.917,3.167 3.917,3.167 4.083,3.167 false 3.25,3.063 3.333,3.417 3.333,3.417 3.5,3.417 false 3,2.865 2.833,2.5 2.833,2.5 2.667,2.5 false 1.708,2.833 2.542,2.833 false 1.75,2.25 2.167,2.25 false 0.75,2 0.75,2.333 false 0.927,3.448 0.75,3.25 0.75,3.25 0.583,3.25 false 0.927,3.448 0.75,3.25 0.75,3.25 0.583,3.25 false 1.271,3.677 1.5,4 1.5,4 1.667,4 false 0.875,3.75 0.875,4.333 false 1.167,3.917 1.167,4.167 1.167,4.167 0.875,4.167 false 2.833,4.917 3.167,4.917 false 2.833,4.5 3.25,4.5 false 3.563,4 3.896,4 false 1.26,1.802 1.417,1.583 1.417,1.583 1.583,1.583 false 1.49,0.802 1.74,0.802 false 0.583,0.833 0.833,0.333 0.833,0.333 1,0.333 false 1.583,0.802 1.583,0.583 1.583,0.583 1.75,0.583 false 4.083,0.667 3.917,0.333 3.917,0.333 3.75,0.333 false 4.01,2.698 4.323,2.896 0.313,0.198 10 false x2 3.708,2.729 4.021,2.927 0.313,0.198 10 false x10 6.625,2.021 6.938,2.219 0.313,0.198 10 false x4 6.365,2.708 6.677,2.906 0.313,0.198 10 false x4 6.833,2.958 7.146,3.156 0.313,0.198 10 false x4 6.656,2.875 6.969,3.073 0.313,0.198 10 false x4 6.375,3.531 6.688,3.729 0.313,0.198 10 false x4 5.958,4.219 6.271,4.417 0.313,0.198 10 false x4 5.729,4.583 6.042,4.781 0.313,0.198 10 false x4 5.417,5.042 5.729,5.24 0.313,0.198 10 false x8 2.729,5.552 3.042,5.75 0.313,0.198 10 false x10 2.844,4.99 3.156,5.188 0.313,0.198 10 false x5 2.781,4.552 3.094,4.75 0.313,0.198 10 false x5 1.5,3.563 1.813,3.76 0.313,0.198 10 false x4 1.094,3.385 1.406,3.583 0.313,0.198 10 false x4 0.938,3.635 1.25,3.833 0.313,0.198 10 false x4 1.188,3.833 1.5,4.031 0.313,0.198 10 false x4 3.146,2.844 3.458,3.042 0.313,0.198 10 false x5 2.281,2.198 2.594,2.396 0.313,0.198 10 false x2 1.323,1.896 1.635,2.094 0.313,0.198 10 false x3 1.625,0.854 1.938,1.052 0.313,0.198 10 false x2 1.708,0.604 2.021,0.802 0.313,0.198 10 false x2 0.438,0.917 0.75,1.115 0.313,0.198 10 false x4 3.479,0.271 3.635,0.448 0.156,0.177 10 false ● 1.25,0.719 1.427,0.906 0.177,0.188 10 false ● 4.729,2.156 4.906,2.344 0.177,0.188 10 false ● 4.625,2.625 4.802,2.813 0.177,0.188 10 false ● 4.333,3.094 4.51,3.281 0.177,0.188 10 false ● 1.469,2.167 1.646,2.354 0.177,0.188 10 false ● 7,2.375 7.125,2.552 0.125,0.177 10 false ● 1.625,1.49 1.802,1.677 0.177,0.188 10 false ● 3.604,0.198 3.896,0.51 0.292,0.313 18 false 1 4.427,3.052 4.719,3.365 0.292,0.313 18 false 1 4.875,2.104 5.167,2.417 0.292,0.313 18 false 2 4.76,2.594 5.052,2.906 0.292,0.313 18 false 2 5.104,2.885 5.438,3.177 0.333,0.292 18 false 12 5.385,1.156 5.677,1.469 0.292,0.313 18 false 6 6.771,3.25 7.063,3.563 0.292,0.313 18 false 5 6.521,3.927 6.875,4.219 0.354,0.292 18 false 11 6.49,4.427 6.854,4.708 0.365,0.281 18 false 13 3.479,4.813 3.854,5.115 0.375,0.302 18 false 10 3.479,4.365 3.854,4.667 0.375,0.302 18 false 7 4.156,3.906 4.531,4.208 0.375,0.302 18 false 9 3.771,3.292 4.146,3.573 0.375,0.281 18 false 8 2.531,2.375 2.906,2.656 0.375,0.281 18 false 7 1.521,2.698 1.896,2.979 0.375,0.281 18 false 8 1.563,2.135 1.938,2.417 0.375,0.281 18 false 2 1.333,0.667 1.708,0.948 0.375,0.281 18 false 2 0.385,3.125 0.76,3.406 0.375,0.281 18 false 4 1.875,3.927 2.25,4.208 0.375,0.281 18 false 3 0.604,2.365 0.979,2.646 0.375,0.281 18 false 14 1.083,0.25 1.917,0.448 0.833,0.198 8 false 21 (214, 15) 0.583,4.333 1.417,4.531 0.833,0.198 8 false 10 (102, 7) 4.688,4.906 5.104,5.104 0.417,0.198 10 false *T1 2,5.406 2.417,5.604 0.417,0.198 10 false *T2 4.125,0.667 4.438,0.865 0.313,0.198 10 false x2 4.875,1.885 5.188,2.083 0.313,0.198 10 false x2

Procedure Part Name Code
Z101186

Z101188

Z101187

1 RING PIN 11115A (Click here) - -
2 STRAIGHT PIN 11114A (Click here) - -
3 NO. 2 OIL NOZZLE SUB-ASSEMBLY 15709 (Click here) - -
4 NO. 1 OIL NOZZLE SUB-ASSEMBLY 15708 (Click here) - -
5 PISTON PIN - (Click here) - -
6 PISTON RING SET 13011 (Click here) - -
7 CRANKSHAFT BEARING - (Click here) - -
8 CRANKSHAFT THRUST WASHER 11791 (Click here) - -
9 CRANKSHAFT 13411 (Click here) - -
10 CRANKSHAFT BEARING CAP - (Click here) - -
11 CONNECTING ROD BEARING - (Click here) - -
12 PISTON WITH CONNECTING ROD - (Click here) - -
13 CONNECTING ROD BEARING CAP - (Click here) - -
14 NO. 1 VENTILATION CASE 12211 - - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
● Non-reusable part - -
*T1 1st: 38 (387, 28)
2nd: Turn 90° 		*T2 1st: 61 (622, 45)
2nd: Turn 90°

PROCEDURE

Hide 11115A 1.INSTALL RING PIN

a.
A470345C02
0.802,0.094 1.115,0.25 0.313,0.156 10 false *a 0.76,1.458 1.073,1.615 0.313,0.156 10 false *b 6.344,0.802 6.656,0.958 0.313,0.156 10 false *c 3.802,0.271 4.115,0.427 0.313,0.156 10 false *d 4.396,0.823 4.708,0.979 0.313,0.156 10 false *e 3.823,1.51 4.135,1.667 0.313,0.156 10 false *f 3.281,0.135 3.594,0.292 0.313,0.156 10 false *a 3.271,1.417 3.583,1.573 0.313,0.156 10 false *b 4.385,2.125 4.698,2.281 0.313,0.156 10 false *e 0.51,0.125 0.792,0.479 0.281,0.354 18 false i
*a Top Side *b Bottom Side
*c Protrusion Height *d 13 mm (0.512 in.)
*e 12 mm (0.472 in.) *f 14 mm (0.551 in.)


i.

Using a plastic hammer, install 12 new ring pins.

Standard Protrusion Height:

5.0 to 7.0 mm (0.197 to 0.276 in.)




Hide 11434Q 2.INSTALL STRAIGHT PIN

a.
A470346C02
1.031,0.104 1.344,0.26 0.313,0.156 10 false *a 1.094,2.875 1.406,3.031 0.313,0.156 10 false *b 4.156,0.125 4.469,0.281 0.313,0.156 10 false *c 4.177,1.552 4.49,1.708 0.313,0.156 10 false *d 4.198,2.927 4.51,3.083 0.313,0.156 10 false *e 6.094,4.833 6.354,5.083 0.26,0.25 10 false *f 1.948,4.896 2.219,5.167 0.271,0.271 10 false *g 1.51,5.552 1.833,5.76 0.323,0.208 10 false *h 3.948,4.948 4.281,5.188 0.333,0.24 10 false *i 3.583,5.427 3.896,5.698 0.313,0.271 10 false *j 1.479,1.49 1.708,1.729 0.229,0.24 10 false B 2.771,0.563 2.938,0.781 0.167,0.219 10 true B 4.135,0.427 4.365,0.667 0.229,0.24 10 false B 5.25,0.469 5.417,0.688 0.167,0.219 10 true B 4.719,1.25 4.948,1.49 0.229,0.24 10 false B 5.896,4.365 6.125,4.604 0.229,0.24 10 false B 5.552,4.375 5.781,4.615 0.229,0.24 10 false B 3.583,4.604 3.813,4.844 0.229,0.24 10 false B 1.51,4.469 1.74,4.708 0.229,0.24 10 false A 0.896,3.625 1.125,3.865 0.229,0.24 10 false A 2.927,3.094 3.156,3.333 0.229,0.24 10 false A 6.5,2.604 6.729,2.844 0.229,0.24 10 false B 0.458,0.146 0.74,0.5 0.281,0.354 18 false i
*a Front Side *b Rear Side
*c LH Side *d Bottom Side
*e RH Side *f Protrusion Height
*g 22 mm (0.866 in.) *h 10 mm (0.394 in.)
*i 14 mm (0.551 in.) *j 6.0 mm (0.236 in.)


i.

Using a plastic hammer, tap in new straight pins to the cylinder block sub-assembly.

Standard Protrusion Height:
Straight Pin Specified Condition
(A) 11.0 to 13.0 mm (0.433 to 0.512 in.)
(B) 5.0 to 7.0 mm (0.197 to 0.276 in.)




Hide 15709 3.INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY

a.
A465174N03
0.448,0.104 0.729,0.458 0.281,0.354 18 false i

i.

Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 15708 4.INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

a.
A465168N03
0.5,0.094 0.781,0.448 0.281,0.354 18 false i

i.

Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 5.INSTALL PISTON PIN

a.
A472723C02
5.167,3.385 5.583,3.385 true 5.115,3.531 5.531,3.531 true 1.115,5.156 0.958,4.885 0.958,4.885 1.406,5.156 true 0.823,3.521 1.354,4.104 true 5.625,3.271 5.938,3.427 0.313,0.156 10 false *1 5.604,3.458 5.917,3.615 0.313,0.156 10 false *a 0.76,4.719 1.073,4.875 0.313,0.156 10 false *b 0.667,3.385 0.979,3.542 0.313,0.156 10 false *a 0.438,0.104 0.719,0.458 0.281,0.354 18 false i 4.198,0.083 4.479,0.438 0.281,0.354 18 false ii 4.198,1.938 4.479,2.292 0.281,0.354 18 true v 0.427,1.49 0.708,1.844 0.281,0.354 18 false iii 0.448,2.833 0.729,3.188 0.281,0.354 18 false iv 4.188,3.979 4.469,4.333 0.281,0.354 18 false vi
*1 Piston Pin Hole Snap Ring - -
*a Cutout *b Front Mark


i.

Using a screwdriver, install a new piston pin hole snap ring (rear side) at one end of the piston pin hole.


ii.

Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

CAUTION:

Be sure to wear protective gloves.



iii.

Apply a light coat of engine oil to the piston, piston pin and connecting rod.


iv.

Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the snap ring.

HINT:

The piston and piston pin are a matched set.



v.

Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

NOTICE:

Make sure that the end gap of the snap ring is not aligned with the cutout of the piston pin hole.



vi.

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

HINT:

Perform "Inspection After Repair" after replacing the piston.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION




Hide 13011 6.INSTALL PISTON RING SET

a.
A465175C03
2.969,1.083 3.135,1.083 false 2.917,1.292 3.083,1.292 false 2.979,1.479 3.146,1.479 false 5.01,1.531 5.01,1.865 true 4.333,0.573 4.573,0.896 true 4.01,1.813 4.385,1.521 true 4.479,1.958 4.854,1.667 true 6,3.24 5.385,2.771 5.385,2.771 6.417,3.125 true 6.063,4.531 5.448,4.063 5.448,4.063 6.594,4.542 true 3.177,1.01 3.49,1.167 0.313,0.156 10 false *1 3.135,1.219 3.448,1.375 0.313,0.156 10 false *3 3.177,1.417 3.49,1.573 0.313,0.156 10 false *2 3.958,0.51 4.406,0.719 0.448,0.208 10 false *1,*2 4.927,1.875 5.24,2.073 0.313,0.198 10 false *a 3.719,2.854 4.031,3.01 0.313,0.156 10 false *e 4.385,3.74 4.698,3.896 0.313,0.156 10 false *d 3.729,4.281 4.042,4.438 0.313,0.156 10 false *f 0.51,0.125 0.792,0.479 0.281,0.354 18 false i 4.198,0.104 4.479,0.458 0.281,0.354 18 false ii 0.521,2.219 0.802,2.573 0.281,0.354 18 false iii 3.813,1.781 4.125,1.979 0.313,0.198 10 false *b 4.281,1.938 4.594,2.135 0.313,0.198 10 false *c 6.5,1.271 6.813,1.469 0.313,0.198 10 false *g 2.948,4.177 3.26,4.375 0.313,0.198 10 false *h 5.156,2.677 5.469,2.833 0.313,0.156 10 false *3 5.208,3.99 5.521,4.146 0.313,0.156 10 false *3
*1 Upper Side Rail *2 Lower Side Rail
*3 Oil Ring Expander - -
*a Code Mark (T) *b Paint (Orange)
*c Paint (Light Green) *d Ring End
*e Correct *f Incorrect (Ends of the oil ring expander are overlapping)
*g Upper Side *h Press around the circumference


i.

Install the oil ring expander, upper side rail and lower side rail to the piston by hand.


ii.

Install the upper side rail and lower side rail to the piston.

NOTICE:

When installing the upper side rail and lower side rail, the ends of the oil ring expander may overlap. If it occurs, the upper side rail or lower side rail may move out of its groove.



iii.

Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

NOTICE:
·

After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.

·

If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.

·

If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander using a screwdriver.





b.
A472722C02
1.167,2.167 1,2.01 false 1.094,2.698 0.927,2.542 false 2.125,2.563 1.792,2.563 true 1.708,2.427 1.458,2.427 true 2.115,2.063 1.781,2.063 true 1.365,3.604 1.365,3.406 false 2.302,3.604 2.302,3.406 false 4.948,1.49 4.865,1.156 4.865,1.156 4.698,1.156 true 0.823,1.938 1.135,2.094 0.313,0.156 10 false *1 0.75,2.448 1.063,2.604 0.313,0.156 10 false *2 2.167,1.979 2.479,2.135 0.313,0.156 10 false *b 4.344,1.854 4.656,2.01 0.313,0.156 10 false *f 5.135,0.979 5.635,1.177 0.5,0.198 10 false *d, *g 1.271,2.344 1.573,2.51 0.302,0.167 10 false *a 2.177,2.49 2.49,2.646 0.313,0.156 10 false *b 1.281,3.625 1.594,3.781 0.313,0.156 10 false *1 2.219,3.615 2.531,3.771 0.313,0.156 10 false *2 5.125,2.708 5.698,2.958 0.573,0.25 10 false *e, *h 4.5,1.063 4.813,1.219 0.313,0.156 10 false *c 0.583,0.135 0.865,0.49 0.281,0.354 18 false i 4.146,0.125 4.427,0.479 0.281,0.354 18 false ii
*1 No. 1 Compression Ring *2 No. 2 Compression Ring
*a Code Mark *b Paint Mark
*c Front Mark *d No. 1 Compression Ring
*e No. 2 Compression Ring *f Oil Ring Expander
*g Lower Side Rail *h Lower Side Rail
V100135

Upward
V100136

Front of Engine


i.

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the paint marks are positioned as shown in the illustration.

Piston Ring Mark:
Item Code Mark Paint Mark
No. 1 Compression Ring - White
No. 2 Compression Ring 2T or 2FTE Sky Blue


NOTICE:

Install the No. 2 compression ring with the code mark (2T or FTE2) facing upward.



ii.

Position the piston ring set so that the ring ends are as shown in the illustration.

HINT:

Perform "Inspection After Repair" after replacing the piston ring.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION




Hide 7.INSTALL CRANKSHAFT BEARING

a.
A483048C02
5.917,4 6.083,4 6.083,4 6.24,4.375 false 0.573,0.125 0.854,0.479 0.281,0.354 18 false i 0.625,1.802 0.906,2.156 0.281,0.354 18 false ii 4.177,1.844 4.458,2.198 0.281,0.354 18 false iii 4.854,3.948 5.135,4.302 0.281,0.354 18 false iv 2.125,5.438 2.438,5.635 0.313,0.198 10 false *a 2.969,5.438 3.281,5.635 0.313,0.198 10 false *b 4.635,4.792 4.948,4.99 0.313,0.198 10 false A 6.094,4.792 6.406,4.99 0.313,0.198 10 false B 5.719,3.917 6.031,4.115 0.313,0.198 10 false *c
*a Correct *b Incorrect
*c Vernier Caliper - -


i.

Clean the main journal and both surfaces of the No. 1 crankshaft bearings and No. 2 crankshaft bearings.


ii.

Install the 5 No. 1 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

NOTICE:

Do not apply engine oil to the No. 1 crankshaft bearings or the contact surfaces.


HINT:

Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the No. 1 crankshaft bearing. The amount visible on each side of the holes should be equal.



iii.

Install the 5 No. 2 crankshaft bearings to the 5 crankshaft bearing caps.

NOTICE:

Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.



iv.

Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and No. 2 crankshaft bearing edge.

Difference between (A) and (B):

0 to 0.9 mm (0 to 0.0354 in.)




Hide 11791 8.INSTALL CRANKSHAFT THRUST WASHER

a.
A464630N01
0.969,0.188 1.25,0.542 0.281,0.354 18 true i 2.896,1.26 3.188,1.563 0.292,0.302 18 true ii

i.

Install the 2 crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.


ii.

Apply engine oil to the crankshaft thrust washers.



Hide 13411 9.INSTALL CRANKSHAFT

a.
A483033N01
0.365,0.052 0.646,0.406 0.281,0.354 18 false i

i.

Apply engine oil to the upper crankshaft bearings and install the crankshaft to the cylinder block sub-assembly.



Hide 10.INSTALL CRANKSHAFT BEARING CAP

a.
A483035C02
1.302,4.979 1.625,4.781 true 4.25,1.542 4.583,1.74 true 2.042,4.396 2.542,4.396 true 0.969,0.125 1.25,0.479 0.281,0.354 18 true i 4.333,0.094 4.615,0.448 0.281,0.354 18 true ii 4.271,2.01 5.146,2.323 0.875,0.313 18 false iv, v, vi 0.802,2.188 1.083,2.542 0.281,0.354 18 true iii 1.156,4.021 1.688,4.375 0.531,0.354 18 false viii 2.875,3.906 3.156,4.26 0.281,0.354 18 true ix 4.302,3.969 4.573,4.302 0.271,0.333 18 true x 1.375,5.281 1.802,5.625 0.427,0.344 18 true vii 4.646,1.708 4.958,1.906 0.313,0.198 10 false *a 4.781,2.25 4.917,2.417 0.135,0.167 10 true 7 5.146,2.26 5.292,2.458 0.146,0.198 10 true 3 5.458,2.25 5.594,2.427 0.135,0.177 10 true 1 5.813,2.25 5.948,2.427 0.135,0.177 10 true 5 6.156,2.25 6.292,2.427 0.135,0.177 10 true 9 6.156,3.26 6.354,3.438 0.198,0.177 10 true 10 5.844,3.26 6.042,3.438 0.198,0.177 10 true 6 5.5,3.281 5.698,3.458 0.198,0.177 10 true 2 5.146,3.281 5.344,3.458 0.198,0.177 10 true 4 4.802,3.281 5,3.458 0.198,0.177 10 true 8 0.51,4.667 0.823,4.865 0.313,0.198 10 false *d 2.604,4.292 2.917,4.49 0.313,0.198 10 false *b 1.198,4.385 1.51,4.583 0.313,0.198 10 false *c 1.146,4.958 1.458,5.156 0.313,0.198 10 false *b
*a Front Mark *b Paint Mark
*c 90° *d Front of Engine


i.

Apply engine oil to the lower crankshaft bearings.


ii.

Confirm the front marks and numbers, and place the 5 crankshaft bearing caps on the cylinder block sub-assembly.


iii.

Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.


iv.

Using a plastic hammer, lightly tap the crankshaft bearing caps to ensure a proper fit.


v.

Install the crankshaft bearing cap set bolts.

NOTICE:

The crankshaft bearing cap set bolts are tightened in 2 progressive steps.



vi.

Uniformly tighten the 10 crankshaft bearing cap set bolts.

Torque:
61 N*m (622 kgf*cm, 45 ft.*lbf)

HINT:

If a crankshaft bearing cap set bolt cannot be tightened to the specified torque, replace it.



vii.

Mark the front of the crankshaft bearing cap set bolts with paint.


viii.

Tighten the 10 crankshaft bearing cap set bolts 90° as shown in the illustration.


ix.

Check that the paint marks are now at a 90° angle to the front.


x.

Check that the crankshaft turns smoothly.



Hide 11.INSTALL CONNECTING ROD BEARING

a.
A464633N01
0.51,2.073 0.792,2.427 0.281,0.354 18 false ii 4.042,2.073 4.323,2.427 0.281,0.354 18 false iii 0.385,0.146 0.667,0.5 0.281,0.354 18 false i

i.

Clean the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap, and both surfaces of the 2 connecting rod bearings.


ii.

Install the 8 connecting rod bearings to the 4 connecting rods and 4 connecting rod caps.


iii.

Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the connecting rod cap and connecting rod bearing.

Difference between (A) and (B):

0 to 0.7 mm (0 to 0.0276 in.)


NOTICE:

Do not apply engine oil to the connecting rod bearings or the contact surfaces.




Hide 12.INSTALL PISTON WITH CONNECTING ROD

a.
A465179C03
3.333,3.292 3.052,3.146 true 3.469,2.74 3.948,2.896 0.479,0.156 10 false *a, *d 3.5,4.563 4.052,4.792 0.552,0.229 10 false *b, *e 2.708,3.646 3.021,3.802 0.313,0.156 10 false *c 2.896,3.042 3.208,3.198 0.313,0.156 10 false *f 0.542,0.313 0.74,0.615 0.198,0.302 18 false i 2.479,2.771 2.677,3.073 0.198,0.302 18 false ii
*a No. 1 Compression Ring *b No. 2 Compression Ring
*c Oil Ring Expander *d Upper Side Rail
*e Lower Side Rail *f Front Mark
V100136

Front of Engine - -


i.

Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.


ii.

Position the piston rings so that the ring ends are as shown in the illustration.



b.
A465180C03
5.875,0.865 5.01,0.406 5.01,0.406 6.573,0.688 true 3.385,3.031 3.531,3.031 3.531,3.031 3.719,3.292 true 5.938,2.198 5.073,1.74 5.073,1.74 6.51,2.135 true 4.792,0.323 5.104,0.521 0.313,0.198 10 false *1 4.875,1.656 5.063,1.865 0.188,0.208 10 true *1 3.563,0.406 3.875,0.604 0.313,0.198 10 false *a 3.573,1.823 3.885,2.021 0.313,0.198 10 false *b 3.167,2.958 3.479,3.156 0.313,0.198 10 false *c 0.719,0.135 1,0.49 0.281,0.354 18 false i 1.563,2.927 1.844,3.281 0.281,0.354 18 false ii 2.896,1.781 3.208,1.979 0.313,0.198 10 false *d 4.313,1.354 4.5,1.531 0.188,0.177 10 false *e
*1 Oil Ring Expander - -
*a Correct *b Incorrect (Ends of the oil ring expander are overlapping)
*c Front Mark *d Press around the circumference
*e Ring End - -


i.

Confirm that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

NOTICE:
·

After installing the oil ring expander, upper side rail and lower side rail, press around the circumference with a finger to check that they are securely installed into the groove.

·

If the oil ring expander is not securely installed into the groove, check that the ends of the oil ring expander are not overlapping.

·

If the ends of the oil ring expander are overlapping, remove the upper side rail and lower side rail and realign the oil ring expander.




ii.

Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston with connecting rod facing the front of the engine.

NOTICE:
·

When inserting the piston with connecting rod into the cylinder block sub-assembly, make sure the connecting rod does not contact the No. 1 oil nozzle sub-assembly.

·

Match each connecting rod cap to the correct connecting rod.





Hide 13.INSTALL CONNECTING ROD BEARING CAP

a.
A483043C01
1.188,0.75 1.854,0.75 true 5.438,3.24 5.438,2.875 true 5.865,2.396 6.135,2.021 true 0.885,0.188 1.24,0.583 0.354,0.396 18 false i 1,0.677 1.313,0.875 0.313,0.198 10 false *a 4.573,0.188 4.958,0.552 0.385,0.365 18 false ii 1,2.208 1.854,2.646 0.854,0.438 18 false iii, iv 5.042,3.167 5.323,3.521 0.281,0.354 18 false v 4.979,1.938 5.365,2.344 0.385,0.406 18 false vi 5.365,3.271 5.677,3.469 0.313,0.198 10 false *b 6.135,1.854 6.448,2.052 0.313,0.198 10 false *b 5.229,2.198 5.542,2.396 0.313,0.198 10 false *c 6.76,2.021 7.156,2.354 0.396,0.333 18 false vii 2.802,4.021 3.292,4.396 0.49,0.375 18 false viii
*a Front Mark *b Paint Mark
*c 90° - -
V100136

Front of Engine - -


i.

Check that the front mark of the connecting rod cap is facing the correct direction.


ii.

Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.


iii.

Install the 8 connecting rod bolts.

NOTICE:

The connecting rod bolts are tightened in 2 progressive steps.



iv.

Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts in several steps.

Torque:
38 N*m (387 kgf*cm, 28 ft.*lbf)


v.

Mark the front of the connecting rod bolts with paint.


vi.

Tighten the connecting rod bolts 90° as shown in the illustration.


vii.

Check that the paint marks are now at a 90° angle to the front.


viii.

Check that the crankshaft turns smoothly.



Hide 13411 14.INSTALL NO. 1 VENTILATION CASE

Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)