CYLINDER BLOCK ASSEMBLY (I)

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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

  Caution
  • Assemble the SST (49 E011 001A) and the SST (49 L011 006A) so that they do not protrude from the outer surface of the piston pin.
  If the SSTs protrude from the outer surface of the piston pin, the piston may be damaged at the time of compression.

1. Assemble the SSTs as shown in the figure.

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2. Assemble the SST (49 D011 002B) and the SST (49 L011 005) to the SST (49 L011 011).

3. Adjust the SST (49 L011 005) and adjust dimension L shown in the figure to the following values.

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  Dimension L

  ZJ: 61.35 mm {2.415 in}
  ZY, Z6: 61.85 mm {2.435 in}

4. Assemble the connecting rod and piston to insert the piston pin. At this time, point the alignment mark on the connecting rod and the F mark on the piston in the same direction.

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5. Insert the piston pin assembled with the SSTs into the piston and connecting rod.

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6. Set the SSTs as shown in the figure. At this time, point the piston head in the direction of the arrow on the SST (49 D011 002B) and align the piston hole position with the SST hole position. In addition, set the piston on the SST (49 D011 002B) horizontally.

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  Caution
  • To prevent the piston from tilting when the hydraulic press contacts the SST (49 L011 006A), support the piston by hand until the hydraulic press contacts the SST.
  If the piston is tilted, it may be damaged at the time of compression.

7. Press fit the piston pin until the lower end of the SST (49 E011 001A) contacts the SST (49 L011 005) using a hydraulic press.

  • If the pressure force is not within the standard, replace the piston pin or the connecting rod.

  Pressure force

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

8. Inspect dimension L shown in the figure.

  • If dimension L is not within the standard, press fit the piston pin again. (See Piston pin re-assembly procedure.)
  • If dimension L is not within the standard, record the difference between the standard value and measurement value because it is necessary to adjust dimension L of the SST again (record as minus value if the measured value exceeds the upper limit of the standard value, and record as plus value if the measured value is less than the lower limit of the standard value).

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  Standard dimension L

  ZJ: 0.85 — 1.85 mm {0.034 — 0.072 in}
  ZY, Z6: 0.35 — 1.35 mm {0.014 — 0.053 in}

Piston pin re-assembly procedure

1. Press out the piston pin. (See CYLINDER BLOCK DISASSEMBLY (II).)

2. Press fit the piston pin again according to the [Piston Pin Assembly Note] procedures. However, correct dimension L of the SST. (See Piston Pin Assembly Note.)

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°