Part 1

ENGINE UNIT

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

REASSEMBLY (STEPS 1 - 9)

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. ASSEMBLE PISTON AND CONNECTING ROD





a) Using a screwdriver, install a new snap ring on one side of the piston pin hole.





b) Gradually heat the piston to about 60°C (140°F).





c) Coat the piston pin with engine oil.
d) Position the piston so that the front mark and to the outside mark on the connecting rod face in the same direction as shown in the illustration.

NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

e) Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.





f) Using a screwdriver, install a new snap ring on the other side of the piston pin hole.

2. INSTALL PISTON RINGS





a) Install the oil ring expander and 2 side rails by hand.
b) Using a piston ring expander, install the 2 compression rings.

Code Mark:

c) Position the piston rings so that the ring ends are as shown.

NOTICE: Do not align the ring ends.

3. INSTALL BEARINGS





a) Align the bearing claw with the groove of the connecting rod or connecting cap.
b) Install the bearings in the connecting rod and connecting rod cap.

4. INSTALL MAIN BEARINGS





HINT:
- Main bearings are of 19.5 mm (0.768 inch) and 22.5 mm (0.886 inch) in width. Install the 22.5 mm (0.886 inch) bearings in the No. 1 and No.5 cylinder block journal positions with the main bearing cap. Install the 19.5 mm (0.768 inch) bearings in the other positions.
- Upper bearings have an oil groove and oil holes, but lower bearings do not.





a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.





b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

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

5. INSTALL CRANKSHAFT THRUST WASHERS





a) Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.





b) Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.

6. INSTALL CRANKSHAFT





a) Place the crankshaft on the cylinder block.
b) Install the 5 main bearing caps in their proper locations.

HINT:
^ The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
^ If any one of the main bearing cap bolts is broken or deformed, replace it.





c) Apply a light coat of engine oil to the threads and under the main bearing cap bolts.
d) Install and uniformly tighten the 10 main bearing cap bolts in several steps, in the sequence shown.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.





e) Mark the front of the main bearing cap bolt with paint.
f) Retighten the main bearing cap bolts by 90° in the numerical order shown.
g) Check that the painted mark is now at a 90° angle to the front.
h) Check that the crankshaft turns smoothly.

7. CHECK CRANKSHAFT THRUST CLEARANCE
8. INSTALL PISTON AND CONNECTING ROD ASSEMBLY





a) Using a piston ring compressor, push correctly the numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTICE: The shape of the piston differs for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

9. PLACE CONNECTING ROD CAP ON CONNECTING ROD





a) Match the numbered connecting rod cap with the connecting rod.
b) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.





c) Check that the outside mark of the connecting rod cap is facing in correct direction.