CYLINDER BLOCK (I) ASSEMBLY

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1.  Assemble in the order indicated in the table.

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1
Upper cylinder block
2
Oil jet valve
3
Upper main bearing
(See Main Bearing Assembly Note)
4
Crankshaft
5
Lower main bearing
(See Main Bearing Assembly Note)
6
Lower cylinder block
(See Lower Cylinder Block Assembly Note)
7
Connecting rod
8
Piston
(See Piston Assembly Note)
9
Piston pin
(See Piston Pin Assembly Note)
10
Piston ring
(See Piston Ring Assembly Note)
11
Piston, connecting rod
12
Upper connecting rod bearing
(See Connecting Rod Bearing Assembly Note)
13
Lower connecting rod bearing
(See Connecting Rod Bearing Assembly Note)
14
Connecting rod cap
(See Connecting Rod Cap Assembly Note)


Main Bearing Assembly Note

Caution
•  If a main bearing is reused, mistaking the position and direction of the bearing could result in engine damage due to seizure or burning of the bearing. Using the identifier paint marks employed during removal, assemble the main bearings at the positions numbered when the journal was removed, and so that the painted areas are on the front sides.

1.  Assemble the upper and lower main bearing as specified shown in the figure.

Caution
•  If the lower main bearing is not assembled according to the specification it could result in engine damage from seizure or burning of the bearing. Measure the bearing using a vernier caliper and assemble it within the specification.
Upper main bearing
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Lower main bearing
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Lower Cylinder Block Assembly Note

1.  Apply silicone sealant to the lower cylinder block attachment side as shown in the figure.

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2.  Apply clean engine oil to the lower cylinder block installation bolts A.

3.  Tighten the lower cylinder block installation bolts A in two steps in the order shown in the figure.

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(1)Tightening torque
23.7—26.3 N·m
{2.42—2.68 kgf·m, 17.5—19.3 ft·lbf}
(2)Tightening angle
42.5°—47.5°

4.  Tighten the lower cylinder block installation bolts B in the order shown in the figure.

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Tightening torque
18.7—25.4 N·m {1.91—2.59 kgf·m, 13.8—18.7 ft·lbf}

5.  Loosen bolts A and tighten the lower cylinder block installation bolts in two steps in the order shown a second time.

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(1)Tightening torque
23.7—26.3 N·m
{2.42—2.68 kgf·m, 17.5—19.3 ft·lbf}
(2)Tightening angle
42.5°—47.5°


Piston Assembly Note

Note
•  After a piston with identification (F) on its upper end is installed, perform the PCM reprogramming, referring to the Workshop Manual, to prevent damage to the engine.
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1.  Position the end gap of each oil ring as shown in the figure.

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2.  Insert the piston into the cylinder with the mark on top of the piston facing the front of the engine.

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Piston Pin Assembly Note

1.  Assemble the SSTs as shown in the figure.

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2.  Adjust the SSTs (stopper bolt) to the L length.

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Standard L length
ZJ: 61.35 mm {2.415 in}
ZY, Z6: 60.85 mm {2.396 in}

3.  Point the end mark on the connecting rod and F- mark on the piston in the same direction as shown in the figure.

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4.  Insert the assembled piston pin and the SSTs into the piston and the connecting rod.

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5.  Set the SSTs as shown in the figure.

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6.  Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt) using the hydraulic press. If it is less than the specification, replace the piston pin or the connecting rod.

Pressure force
2940—14700 N {300—1498 kg, 660—3297 lbf}


Piston Ring Assembly Note

1.  Assemble the oil ring.

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2.  Install the second ring with the notch facing downward.

3.  Install the top ring with scraper face side upward.


Connecting Rod Bearing Assembly Note

Caution
•  If a connecting rod bearing is reused, mistaking the position and direction of the bearing could result in engine damage due to seizure or burning of the bearing.
Using the identifier paint marks employed during removal, assemble the main bearings at the positions numbered when the journal was removed, and so that the painted areas are on the front sides.

1.  Install the connecting rod bearing to the connecting rod and the connecting rod cap as specified shown in the figure.

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Caution
•  If the connecting rod bearing is not assembled according to the specification it could result in engine damage from seizure or burning of the bearing. Measure the bearing using a vernier caliper and install it within the specification.

Connecting Rod Cap Assembly Note

1.  Install the connecting rod cap with the knock pins and the alignment marks aligned.

2.  Tighten the connecting rod cap installation bolt in two steps.

(1)Tightening torque
ZJ: 17.2—22.0 N·m
{1.75—2.24 kgf·m, 12.7—16.2 ft·lbf}
ZY, Z6: 22.1—26.9 N·m
{2.26—2.74 kgf·m, 16.3—19.8 ft·lbf}
(2)Tightening angle
ZJ: 85°—95°
ZY, Z6: 82.5°—97.5°