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c. Install the main bearings paying attention to the direction.
Install the one with oil holes onto the cylinder block and the
one without oil holes onto the main bearing cap.
Before installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.
When installing, align the bearing stopper to the notch.
Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
4. Install the pilot converter to the crankshaft using suitable tool.
5. Install the crankshaft to the cylinder block.
While turning the crankshaft by hand, make sure it turns
smoothly.
6. Install the main bearing caps.
Align the identification number to the journal position to install.
Install it with front mark (indicated by the arrow) facing front of
engine.
Tap the caps lightly to seat them on the installation position.
7. Follow the steps below to tighten each main bearing cap bolt.
a. Apply engine oil to threads and seating surfaces of bolts, and
tighten all bolts temporarily.
b. Measure tightening angle using Tool.
CAUTION:
Measure tightening angle using Tool. Do not measure visu-
ally.
PBIC0094E
EMP0569D
KBIA2533E
Main bearing cap bolts
in order of 1 to 10: 39.2 N·m (4.0 kg-m, 29 ft.-lb)
Main bearing cap sub
bolts in order of 11 to 20: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC0090E
Tool number : KV10112100 (BT-8653-A)
Main bearing cap bolts in
order of 1 to 10: 40°
WBIA0597E
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Revision: August 20072004 QX56Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
Check the crankshaft side clearance. Refer to EM-89, "CRANKSHAFT END PLAY" .
8. Install rear oil seal to rear oil seal retainer.
CAUTION:
Do not damage or scratch outer circumference of oil seal.
Install new rear oil seal in the direction shown.
Tap until flattened with front edge of rear oil seal retainer
using suitable tool.
Fit the rear oil seal until it is level with the rear end surface of
rear oil seal retainer.
9. Install rear oil seal retainer.
Apply liquid gasket to rear oil seal retainer as shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Products and Sealants".
Apply new engine oil on lips of rear oil seal. Do not touch.
10. Install the piston to the connecting rod.
a. Install the snap ring to the grooves of the piston rear side.
Insert it fully into groove to install.
b. Install the piston to the connecting rod.
Heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60° to 70 C°
(140° to 158 °F)]. From the front to the rear, insert the piston pin into the piston and the connecting rod. Main bearing cap sub
bolts in order of 11 to 20: 30°
Side bolts in order of 21 to
30: 49 N·m (5.0 kg-m, 36 ft-lb)
SEM 71 5A
PBIC0097E
SBIA0391E
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Assemble so that the front mark on the piston crown and the
oil holes and the cylinder No. on the connecting rod are posi-
tioned as shown.
c. Install the snap ring to the grooves of the piston front side.
Insert it fully into groove to install.
After installing, make sure the connecting rod moves
smoothly.
11. Install the piston rings.
CAUTION:
Be careful not to damage the piston.
Position each ring with the gap as shown, referring to the pis-
ton front mark.
Install the second ring with the stamped surface facing
upward.
12. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
When installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of the connecting rod to install.
Check the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft
using Tool.
Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
Apply engine oil sufficiently to the cylinder bore, piston, and
crankshaft pin.
Match the cylinder position with the cylinder No. on the con-
necting rod to install.
Install the piston with the front mark on the piston crown fac-
ing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from an interference of the connecting
rod big end.
KBIA2534E
Stamped mark Second ring : 2N
PBIC0100E
PBIC0266E
Tool number : EM03470000 (J-8037)
KBIA2535E
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14. Install the connecting rod cap.
Match the stamped cylinder number marks on the connecting
rod with those on the cylinder cap to install.
15. Tighten the connecting rod bolts using Tool.
Apply engine oil to the threads and seats of the connecting
rod bolts.
After tightening the bolts, make sure that the crankshaft
rotates smoothly.
Check the connecting rod side clearance. Refer to EM-89, "CONNECTING ROD SIDE CLEARANCE"
16. Install knock sensor.
CAUTION:
If the knock sensor is dropped, replace it with a new one.
Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of the knock sen-
sor.
Install it with its connector facing the center of cylinder block
side.
Do not tighten the knock sensor bolts while holding the con-
nector.
Make sure that the knock sensor does not interfere with other
parts.
Position sub-harness as shown before installing intake mani-
fold.
17. Installation of the remaining components is in the reverse order of removal.
18. Remove engine assembly from engine stand.
KBIA2536E
Tool number : KV10112100 (BT-8653-A)
Connecting rod bolts
Step 1 : 19.6 N·m (1.5 kg-m, 11 ft-lb)
Step 2 : 90° clockwise
WBIA0586E
KBIA2493E
KBIA2549E
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19. Install drive plate.
Align dowel pin of crankshaft rear end with pin holes of each
parts to install.
Install drive plate, reinforcement plate and pilot converter (if
not installed in step 4) as shown.
Face chamfered or rounded edge side to crankshaft.
How to Select Piston and Bearing EBS00ILY
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The information at the shipment from the plant is described as a reference.
The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards, and the selection method of the
selective fitting parts, refer to the text.
KBIA2494E
KBIA2537E
Connecting points Connecting parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (Housing inside diame-
ter) and crankshaft journal
grade (journal outside diame-
ter)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Connecting rod bearing grade
= crankshaft pin grade (pin
diameter). No grade exists for
inside diameter of connecting
rod large end.
Between cylinder block to pis-
tonPiston and piston pin assembly.
The piston is available together
with piston pin as an assembly.Piston grade (piston diameter)Piston grade = cylinder bore
grade (diameter of bore)
*Between piston to connecting
rod———
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HOW TO SELECT PISTON
Piston Selective Fitting When New Cylinder Block is Used:
Check the cylinder bore grade on the bottom face of cylinder
block, and select the piston of the same grade.
When Cylinder Block is Reused
1. Measure the cylinder block bore diameter.
2. Determine the bore grade by comparing the measurement with the values under the “Cylinder bore diam-
eter” of the piston selection table. Use oversized piston if clearance of standard grade piston is outside the
specified value.
Piston Selection Table
Unit: mm (in)
CAUTION:
Oversize must be used in all cylinders when using oversized parts.
NOTE:
The piston is available together with piston pin as an assembly.
The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts,
no grades can be selected (Only 0 grade is available.).
Hone cylinder to obtain specified clearance between piston and cylinder bore when using an oversized
piston. Be sure to use the same oversized piston rings.
KBIA2495E
KBIA2496E
Grade number (Mark) 1 2 3
Cylinder bore diameter 98.000-98.010 (3.8583-3.8587) 98.010-98.020 (3.8587-3.8590) 93.020-98.030 (3.8590-3.8594)
Piston diameter 97.980-97.990 (3.8575-3.8579) 97.990-98.000 (3.8579-3.8583) 98.000-98.010 (3.8583-3.8587)
Piston oversize (Service) : 0.20 mm (0.0079 in)
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HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
1. Apply big end inside diameter grade stamped on connecting rod
side face to the row in the “Connecting Rod Bearing Selection
Table”.
2. Apply pin diameter grade stamped on crankshaft front side to
the column in the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column
in the “Connecting Rod Bearing Selection Table”.
4. Apply the symbol obtained to connecting rod bearing grade table
to select.
When Crankshaft and Connecting Rod are Reused
1. Measure dimensions of the big end inside diameter of connecting rod and diameter of crankshaft pin indi-
vidually.
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. The following steps are same as in “When New Connecting Rod and Crankshaft are Used”. Refer to EM-
84 .
Connecting Rod Bearing Selection Table
Connecting Rod Bearing Grade Table
KBIA2536E
PBIC0 110 E
KBIA2538E
Grade number Thickness “T” mm (in) Identification color (mark)
0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
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Undersize Bearings Usage Guide
When the specified oil clearance is not obtained with standard size connecting rod bearings, use under-
size (US) bearings.
When using undersize bearing, measure the bearing inside diameter with bearing installed, and grind the
crankshaft pin so that the oil clearance satisfies the standard.
Bearing undersize table
Unit: mm (in)
CAUTION:
In grinding the crankshaft pin to use undersize bearings, keep
the fillet R (All crankshaft pins).
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
1. Apply main bearing housing grade on bottom face of cylinder
block to the row in the "Main Bearings Selection Table".
2. Apply journal diameter grade on crankshaft front to the column
in the "Main Bearings Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Main Bearings Selection Table".
CAUTION:
Initial clearance for No.1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection
lists for each part.
No.1, 5 journal and No. 2, 3, 4 journal have the same signs but different measures. Do not con-
fuse.
4. Apply the symbol to the "Main Bearings Grade Table" to select.
NOTE:
Grade list applies to all journals.
Service parts are available as a set of both upper and lower.
2 1.506 - 1.509 (0.0593 - 0.0594) Green
3 1.509 - 1.512 (0.0594 - 0.0595) Yellow
Undersize Thickness
0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644)
Fillet R : 1.5 - 1.7 mm (0.059 - 0.067 in)
PB I C 0 111E
KBIA2495E
PBIC0 110 E