Cylinder Block: Installation

• RH side

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• LH side

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Preparation items: 

Liquid gasket: THREE BOND 1217G (part No. K0877Y0100), THREE BOND 1217H or equivalent

Liquid gasket applying diameter: 

Mating surfaces other than ranges A, B and C 

1±0.5 mm (0.0394±0.0197 in)

Mating surfaces of ranges A and C 

4±0.5 mm (0.1575±0.0197 in)

Mating surfaces of range B 

3.2 ±0.5 mm (0.1260±0.0197 in)

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1. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.
   NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount.
2. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
3. Loosen all mounting bolts by 180° in the reverse order of tightening in step (2).
4. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
5. Loosen the mounting bolts (4 places) by 180° in the order of 6 → 5 → 4 → 3 as shown in the figure.
6. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in the order of 3 → 4 → 5 → 6 as shown in the figure.
7. Using an angle gauge, tighten the mounting bolts (4 places) by 58 - 62° in the order of 3 → 4 → 5 → 6 as shown in the figure.
8. Loosen the mounting bolts (6 places) by 180° in the order of 8 → 7 → 10 → 9 → 2 → 1 as shown in the figure.
9. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in the order of 1 → 2 → 9 → 10 → 7 → 8 as shown in the figure.
10. Using an angle gauge, tighten the mounting bolts (3 places) by 58 - 62° in the order of 1 → 2 → 9 as shown in the figure.
11. Using an angle gauge, tighten the mounting bolt 10 (1 place) shown in the figure by 78 - 82°.
12. Using an angle gauge, tighten the mounting bolt 7 (1 place) shown in the figure by 58 - 62°.
13. Using an angle gauge, tighten the mounting bolt 8 (1 place) shown in the figure by 78 - 82°.
    Fig 1: Cylinder Block Mounting Bolts Tightening Sequence

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14. Install the bolt shown in the figure.
    NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surfaces of the chain cover and oil pan upper, remove any squeezed-out liquid gasket. Any liquid gasket on the chamfer area, however, should not be removed.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb)

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15. Remove the wood board, etc. securing the connecting rod on the cylinder block RH side.
    CAUTION: Before removing the wood board, etc, wrap the connecting rod small end on the cylinder block RH side with cloth, etc. to protect the cylinder.

Preparation tool: 

ST1: ENGINE STAND ADAPTER RH (498457000)

ST2: ENGINE STAND ADAPTER LH (498457100)

ST3: ENGINE STAND (499817100)

Tightening torque: 

35 N.m (3.6 kgf-m, 25.8 ft-lb)

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1. Set the part so that the chain cover side is on the upper side.
2. Remove the protective cloth, etc. wrapped around the connecting rod small end of the #1 cylinder and #2 cylinder.
3. Using the ST, turn it until the connecting rod small ends of #1 cylinder and #2 cylinder are aligned with the service hole (near the bottom dead position).
   NOTE: While turning, check the connecting rod position from the cylinder and service hole.

   Preparation tool: 

   ST: CRANKSHAFT SOCKET (18252AA000)

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4. Check that the circlip installation position and the piston ring gap for each piston are positioned correctly. Ref. to MECHANICAL (H4DO)>CYLINDER BLOCK>ASSEMBLY>PISTON .
5. Compress the piston ring using piston ring compressor, and insert the pistons of #1 cylinder and #2 cylinder into cylinder block.
   NOTE:

   • Apply engine oil to the outer circumference of the piston and in the cylinder block.
   • Before inserting the piston, move the connecting rod to around the center of the cylinder.
   • Face the piston front mark (round mark) towards the front of the engine.
     • RH side

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     (a)	Front mark

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     (a)	Front mark

   • Insert until the piton pin hole and the connecting rod small end are almost at the same position while lightly tapping the crown of the piston with the handle of a plastic hammer and while checking the position of the piston pin hole and the connecting rod small end from the service hole.
   • RH side

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   • LH side

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6. Using the ST, align the position of the piston pin hole and the connecting rod small end.
   CAUTION: To prevent the circlip installed to the piston from falling off, use special care not to apply excessive force to the circlip while aligning the position using the ST.
   NOTE: Apply a thin coat of engine oil to the ST.

   Preparation tool: 

   ST: PISTON PIN GUIDE (18253AA000)

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7. Apply a thin coat of engine oil to piston pins, and insert them into pistons and connecting rods of #1 cylinder and #2 cylinder.
8. Install new circlips to the piston.
   CAUTION:

   • When installing the circlip using long-nose pliers, do not allow the circlip claw sections to contact with each other as shown in the figure.

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     (a)	Gap between the circlip claw sections: 1 mm (0.0394 in) or more

   • After operation, make sure the circlip is firmly installed on the circlip groove of the piston.
   • If the circlip needs to be reinstalled after installed to the piston, the circlip cannot be reused. Use a new circlip.

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9. Set the part so that the rear oil seal side is on the upper side.
   CAUTION: When moving the cylinder block, be careful not to damage the cylinder block by the connecting rod.
10. Following the same procedures as used for #1 cylinder and #2 cylinder, set the piston to the #3 cylinder and #4 cylinder and install the piston pins to the pistons and connecting rods.
11. Install the service hole plug to the cylinder block RH.
    CAUTION: Always use a new service hole plug.
    NOTE: Before installing the service hole plug, degrease the thread portion for securing service hole plug of the cylinder block RH.

    Tightening torque: 

    70 N.m (7.1 kgf-m, 51.6 ft-lb)

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12. Install new O-rings to the cylinder block LH.

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13. Install the service hole cover to the cylinder block LH.
    1. Tighten the bolts with a torque of 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) in numerical order 1 → 2 as shown in the figure.
    2. Tighten the bolt 1 shown in the figure with a torque of 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) again.
       NOTE: This procedure is necessary to stabilize torque.

Fig 2: Service Hole Cover Bolts Tightening Sequence

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Preparation tool: 

ST1: OIL SEAL GUIDE (18671AA020)

ST2: OIL SEAL INSTALLER (18657AA030)

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Tightening torque: 

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

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Preparation tool: 

ST1: BOLT (90119-14120)

ST2: ENGINE HANGER NO. 1 (12281-38150)

Tightening torque: 

43 N.m (4.4 kgf-m, 31.7 ft-lb)

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Tightening torque: 

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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