Assembly Of Cylinder Block

(See page EM-181)

HINT:

• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

• Replace all gaskets, O-rings and oil seals with new parts.

1. INSTALL MAIN BEARINGS

HINT:

• Main bearings come in widths of 19.2 mm (0.756 in.) and 22.9 mm (0.902 in.). Install the 22.9 mm (0.902 in.) bearings in the No.3 cylinder block journal position with the main bearing cap. Install the 19.2 mm (0.756 in.) bearings in the other positions.

• Upper bearings have an oil groove and oil holes; lower bearings do not.

em6948

(a) Align the bearing claw with the claw groove of the cylinder block, and push in the five upper bearings.

(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the five lower bearings.

HINT: A number is marked on each main bearing cap to indicate the installation position.

2. INSTALL UPPER THRUST WASHERS

Install the two thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.

3. PLACE CRANKSHAFT ON CYLINDER BLOCK

4. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS

(a) Install the two thrust washers on the No.3 bearing cap with the grooves facing outward.

(b) Install the five main bearing caps in their proper locations.

HINT: Each bearing cap has a number and front mark.

(c) Apply a light coat of engine oil on the threads and under the heads of the main bearing caps.

(d) Install and uniformly tighten the ten bolts of the main bearing caps in several passes in the sequence shown.

(e) Check that the crankshaft turns smoothly.

(f) Check the crankshaft thrust clearance. (See step 5 on page EM-195)

5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES

(a) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

(b) 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.

6. INSTALL CONNECTING ROD CAPS

A. Place connecting rod cap on connecting rod

(a) Match the numbered connecting rod cap with the connecting rod.

(b) Install the connecting rod cap with the front mark facing forward.

B. Install connecting rod cap nuts HINT:

• The cap nuts are tightened in two progressive steps (steps (b) and (d)).

• If any the connecting rod bolt is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the cap nuts.

(b) Using SST, install and alternately tighten the cap nuts in several passes.

SST 09011-38121

If any one of the cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set.

(c) Mark the front of the cap nut with the paint.

Painted Mark

Painted Mark

(d) Retighten the cap nuts 90° in the numerical order shown.

(e) Check that the painted mark is now at a 90° angle to the front.

(f) Check that the crankshaft turns smoothly.

(g) Check the connecting rod thrust clearance. (See step 2 on page EM-193)

INSTALL REAR OIL SEAL RETAINER

Install a new gasket and the retainer with the six bolts. Torque: 95 kg-cm (82 in.-lb, 9.3 N-m)

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