Page 1897 of 4264

ENGINE MECHANICAL (6VE1 3.5L) 6A-73
bolts.
Main bearing cap bolts.
Torque: 39 N
m (4.0 Kg
m/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 N
m (3.0 Kg
m/21 lb ft)
2nd step 55
65
Crank case side bolts
Torque : 39 N
m (4.0 Kg
m/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS006
10. Remove the main bearing caps in the sequence
shown in the illustration.
015RS004
11. Measure the plastigage width and determine the
oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a se
t
and/or replace the crankshaft.
Standard : 0.019 mm
0.043 mm
(0.0007 in
0.0017 in)
Limit : 0.08 mm (0.0031 in)
015RS008
12. Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection
Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions.
Inspection and Repair
1. Carefully set the crankshaft on the Vblocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS007
Page 1898 of 4264

6A-74 ENGINE MECHANICAL (6VE1 3.5L)
2. Measure the diameter and the uneven wear of
main journal and crank pin. If the crankshaft wear
exceeds the specified limit, crankshaft must be
replaced.
Main journal diameter : 63.918 mm
63.933 mm
(2.5165 in.
2.5170 in.)
Crank pin diameter : 53.922 mm
53.937 mm
(2.1229 in.
2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS009
Crankshaft Bearing Selection
Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing
inserts.
1. The grade mark (1) for cylinder block journal are
stamped on the lower face of cylinder block as
shown in the illustration.
RTW31BSH000701
2. The crankshaft journal diameter grade mark (1)
are stamped on the No.1 crankshaft balancer (2)
as shown in the illustration.
015R200005
3. Match the cylinder block journal grade marks and
the crankshaft journal grade marks in the table
below to determine the correct crankshaft bearing
size.
The size color code is painted to side of the
crankshaft bearings.
RTW31BSH000601
Page 1899 of 4264

ENGINE MECHANICAL (6VE1 3.5L) 6A-75
Grade
Mark
Cylinder Block
Journal
Crank Shaft Journal
Diameter
Grade
Mark
Color Code
Oil Clearance
(Reference)
1 68.994-69.000
(2.7163-2.7165) 63.918-63.925
(2.5165-2.5167) 2 Blue 0.024-0.043
(0.0009-0.0017)
63.926-63.933
(2.5168-2.5170) 1 Brown 0.022-0.041
(0.0009-0.0016)
2 68.987-68.993
(2.7160-2.7163) 63.918-63.925
(2.5165-2.5167) 2 0.023-0.042
(0.0009-0.0016)
63.926-63.933
(2.5168-2.5170) 1 Green 0.021-0.040
(0.0008-0.0016)
3 68.980-68.986
(2.7157-2.7160) 63.918-63.925
(2.5165-2.5167) 2 0.022-0.041
(0.0009-0.0016)
63.926-63.933
(2.5168-2.5170) 1 Yellow 0.020-0.039
(0.0008-0.0015)
Reassembly
1. Crankshaft (12)
Install the main bearings to the cylinder block
and the main bearing caps.
Be sure that they are positioned correctly.
Apply new engine oil to the upper and lower
main bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS012
Legend
(1) Numver 1 and 4 main bearing upper and lower
(2) Numver 2 and 3 main bearing upper
(3) Numver 2 and 3 main bearing lower
Carefully mount the crankshaft.
Apply engine oil to the thrust washer.
Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the
crankshaft.
015RS013
2. Rear oil seal (10)
Remove the oil from the cylinder block and the
retainer mounting surface.
Apply sealant (TB1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.
The retainer must be installed within 5 minutes
after sealant application before the sealan
t
hardens.
Page 1900 of 4264

6A-76 ENGINE MECHANICAL (6VE1 3.5L)
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
Apply engine oil to the oil seal lip.
Align the cylinder block dowel pin holes with the
rear retainer dowel pins.
Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 N
m (1.8 Kg
m/13 lb ft)
NOTE: Be very careful not to disengage the oil seal
garter spring during installation of the rear retainer.
If the seal was removed from retainer fo
r
replacement, apply engine oil to the oil seal lip
and install the oil seal using 5884022860 oil
seal installer.
015RW001
015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and
flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Hold the crankshaft to prevent from rotating
then install the bolts in the order shown to the
specified torque.
Torque: 54 N
m (5.5 Kg
m/40 lb ft)
NOTE: Do not reuse the bolt and do not apply oil o
r
thread lock to the bolt.
015RS018
4. Piston and connecting rod assembly (8)
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaf
t
pins. Check to see that the piston ring end gaps
are correctly positioned.
Page 1901 of 4264

ENGINE MECHANICAL (6VE1 3.5L) 6A-77
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
Apply engine oil to the threads and seating
faces of the nuts.
Tighten the nuts.
Torque: 54 N
m (5.5 Kg
m/40 lb ft)
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back
faces.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2
steps, in the order shown.
1st step: 29 N
m (3.0 Kg
m/22 lb ft)
2nd step: 55
65
051RS009
6. Cylinder block side bolts (6)
Tighten all the bolts to the specified torque in
the order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 N
m (4.0 Kg
m/29 lb ft)
Page 1902 of 4264
6A-78 ENGINE MECHANICAL (6VE1 3.5L)
012RS001
7. Install oil pump assembly (5), refer to “Oil pump" in
this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
Torque: 25 N
m (2.5 Kg
m/18 lb ft)
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant,
lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB
1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead.
3. The crankcase assembly must be installed
within 5 minutes after sealant application to
prevent premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified
torque.
Torque : 10 N
m (1.0 Kg
m/7 lb ft)
013RW010
Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion
11. Install cylinder head assembly, refer to “Cylinder
head" in this manual.
Page 1903 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-79
Piston and Connecting Rod
Piston, Connecting Rod and Associate Parts
015RW019
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Gallery
(7) Piston and Connecting Rod Assembly
(8) Piston Ring
(9) Piston Pin
(10) Piston
(11) Connecting Rod
(12) Connecting Rod Cap
Disassembly
1. Remove cylinder head assembly (1). Refer to
“Cylinder Head Removal" in this manual. 2. Remove cylinder head gasket (2).
3. Remove crankcase with oil pan (3). Refer to ”Oil
Pan and Crankcase" in this manual.
4. Remove oil pipe and O-ring (4).
Page 1904 of 4264

6A-80 ENGINE MECHANICAL (6VE1 3.5L)
5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod
lower bearing (12).
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.
015RS031
Remove any ridge or carbon build up from the
top end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
015RS022
10. Remove the piston pin (9) using 5884005510
piston pin service set and piston support with a
press.
NOTE: Keep the parts removed from each cylinde
r
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston fo
r
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
Piston Diameter
1. Measure the piston outside diameter with
micrometer at the piston grading position and a
right angle to the piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)