Page 3497 of 4770

A07352
20.5 mm
S01546
SST
S05573
Cut Position
Pry
S05572
SST
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±105
1277 Author: Date:
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 20.5 mm (0.807 in.)
from the piston head.
(c) Calculate the amount of each cylinder is to be rebored as
follows:
Size to be rebored = P + C ± H
P = Piston diameter
C = Piston oil clearance
0.175 ± 0.195 mm (0.0068 ± 0.0076 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the oil pump is removed from the cylinder block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09226±10010
(3) Apply MP grease to the oil seal lip.
(b) If the oil pump is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09226±10010
Page 3498 of 4770
EM7362
P19502
SST
S06005
Cut position
S06004
SST EM±106
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1278 Author: Date:
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
there are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder
block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223±15030, 09950±70010 (09951±07100)
(3) Apply MP grease to the oil seal lip.
(b) If rear oil seal retainer is installed to cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
Page 3499 of 4770
EM08L±03
A06586
A01776
A07349
Front Mark
(Cavity)
Front Mark
(Protrusion)
A06587
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±107
1279 Author: Date:
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O±rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring on one
side of the piston pin hole.
(b) Gradually heat the piston to 80 ± 90°C (176 ± 194°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Using a small screwdriver, install a new snap ring on the
other side of the piston pin hole.
Page 3500 of 4770

A06588
No.1
No.2Code Mark
Code Mark
A07351
Upper Side Rail
ExpanderFront
Mark
(Cavity) No.1
Compression
Ring
No.2
Compression
RingLower Side Rail
P
P00797
P05533
22.9 mm
19.2 mm Others
No.3
P05353
EM±108
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1280 Author: Date:
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the No.2 and No.1
piston rings with the code mark facing upward.
Code mark:
No.11N or T
No.22N or 2T
(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 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.) bear-
ings 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.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
Page 3501 of 4770

P03177
Mark
1, 2, 3, 4, or 5
P05354
P03173
S06012
P00104
1
10
735
84269
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±109
1281 Author: Date:
(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 UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
(b) Install the 5 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 cap bolts.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes, in the sequence shown.
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(e) Check that the crankshaft turns smoothly.
8. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±86)
Page 3502 of 4770

EM2082
A06614
Push Front Mark
(Cavity)
Front
N01001
Front Mark
(Protrusion)
Z19381
EM±110
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1282 Author: Date:
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
(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 num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
10. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
11. INSTALL CONNECTING ROD CAP NUTS
HINT:
The cap nuts are tightened in 2 progressive steps (steps
(b) and (d)).
If any one of the connecting rod bolts is broken or de-
formed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.
(b) Install and alternately tighten the 2 cap nuts in several
passes.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
If any one of the cap nuts does not meet the torque specifica-
tion, replace the connecting rod bolt and cap nut as a set.
Page 3503 of 4770

S02826
Front 90°Painted Mark
90°
S05945
Pulley
Set
Key
Cylinder
Block Top
Surface
P01478
P00716
P00733
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±111
1283 Author: Date:
(c) Mark the front of the cap nut with the paint.
(d) Retighten the cap nuts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
12. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM±86)
13. INSTALL ENGINE BALANCER
(a) Turn the crankshaft, and set the No.1 cylinder TDC as
shown in the illustration.
(b) Set the balance shafts so that the punch marks of the bal-
ance shafts are aligned with the grooves of the
No.2 housing.
(c) Wipe clean the installation surface of the spacer.
(d) Place the spacers on the cylinder block.
HINT:
When replacing the crankshaft and/or balance shaft, use the
thickest spacers.
(e) Place the engine balancer on the cylinder block.
(f) Check that punch marks shown in the illustration of the
balance shafts are aligned with the grooves of the No.2
housing.
Page 3504 of 4770

S04614
1
Pull 53
426
P01477
Z19357
13
2 EM±112
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1284 Author: Date:
(g) While pulling the center part of the engine balancer in the
direction of the arrow, uniformly tighten the 6 bolts in sev-
eral passes, in the sequence shown.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(h) Recheck that the punch marks of the balance shafts are
aligned with the grooves of the No.2 housing.
14. CHECK AND ADJUST BACKLASH OF CRANKSHAFT
GEAR AND NO.1 BALANCE SHAFT GEAR
(See page EM±86)
15. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
16. INSTALL WATER PUMP, WATER BYPASS PIPE AND
OIL COOLER (w/ OIL COOLER) ASSEMBLY
(a) Install a new O±ring to the water pump cover.
(b) Install the water pump, water bypass pipe and oil cooler
(w/ oil cooler) assembly with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
(c) Install the generator drive belt adjusting bar with the bolt.
Torque: 22 N´m (224 kgf´cm, 16 ft´lbf)
(d) w/ Oil Cooler:
Install the oil cooler. (See page LU±18)
17. INSTALL OIL FILTER (See page LU±2)
18. INSTALL KNOCK SENSOR 1 (See page SF±57)
19. INSTALL PS PUMP BRACKET
Install the PS pump bracket with the 3 bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
20. INSTALL OIL PUMP AND OIL PAN
(a) Install the oil pump and oil pan. (See page LU±13)
(b) Install the crankshaft position sensor connector to the
generator drive belt adjusting bar.
21. INSTALL OIL DIPSTICK
22. INSTALL CYLINDER HEAD ASSEMBLY
(a) Install the cylinder head assembly. (See page EM±33)
(b) Install the 2 bolts holding the water bypass pipe to the cyl-
inder head.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(c) Install the VSV for EGR to the cylinder head with the bolt.
(d) Connect the knock sensor 1 connector.
(e) Connect the crankshaft position sensor connector.