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15. Tighten connecting rod bolts using Tool.
Apply engine oil to threads and seats of connecting rod bolts.
After tightening bolts, make sure the crankshaft rotates
smoothly.
Check connecting rod side clearance. Refer to EM-94, "CON-
NECTING ROD SIDE CLEARANCE" .
16. Install knock sensors. CAUTION:
If 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 knock sensor.
Install it with its connector facing the center of the cylinder
block side.
Do not tighten knock sensor bolts while holding connector.
Make sure knock sensor does not interfere with other parts.
Position the sub-harness as shown before installing intake
manifold.
17. Installation of the remaining components is in the reverse order of removal.
18. Remove engine assembly from engine stand.
19. Install drive plate.
Align dowel pin of crankshaft rear end with pin holes of each
part to install. 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
WBIA0627E
KBIA2493E
KBIA2549E
KBIA2494E
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Install drive plate, reinforcement plate and pilot converter (if
not installed in step 4) as shown.
Face the chamfered or rounded edge side to the crankshaft.
How to Select Piston and Bearing EBS00RFJ
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.
HOW TO SELECT PISTON
Piston Selective Fitting When New Cylinder Block is Used:
Check the cylinder bore grade on the bottom face of the cylinder
block, and select the piston of the same grade.
KBIA2537E
Connecting pointsConnecting parts Selection itemsSelection methods
Between cylinder block to
crankshaft Main bearing
Main 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 rod Connecting rod bearing
Connecting 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-
ton Piston 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 ———
KBIA2495E
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When Cylinder Block is Reused
1. Measure 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 the 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 the cylinder to obtain specified clearance between the piston and cylinder bore when using an over-
sized piston. Be sure to use the same oversized piston rings.
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
1. Apply the big end inside diameter grade stamped on the con- necting rod side face to the row in the “Connecting Rod Bearing
Selection Table ”.
KBIA2496E
Grade number (Mark) 123
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)
KBIA2536E
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2. Apply the pin diameter grade stamped on the crankshaft front
side to the column in the “Connecting Rod Bearing Selection
Ta b l e ”.
3. Read the symbol at the cross point of the selected row and col- umn in the “Connecting Rod Bearing Selection Table ”.
4. Apply the symbol obtained to the "Connecting Rod Bearing Grade Table" to select.
When Crankshaft and Connecting Rod are Reused
1. Measure dimensions of the big end inside diameter of the connecting rod and diameter of the crankshaftpin individually.
2. Apply the measured dimension to the "Connecting Rod Bearing Selection Table".
3. The following steps are the same as in “When New Connecting Rod and Crankshaft are Used ”. Refer to
EM-88, "
HOW TO SELECT CONNECTING ROD BEARING" .
Connecting Rod Bearing Selection Table
Connecting Rod Bearing Grade Table.
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 the bearing installed, and grind
the crankshaft pin so that the oil clearance satisfies the standard.
PBIC0110E
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
2 1.506 - 1.509 (0.0593 - 0.0594) Green
3 1.509 - 1.512 (0.0594 - 0.0595) Yellow
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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 the main bearing housing grade on the bottom face of the
cylinder block to the row in "Main Bearings Selection Table".
2. Apply the journal diameter grade on the crankshaft front to the column in "Main Bearings Selection Table".
3. Read the symbol at the cross point of the 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 them.
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.
When Cylinder Block and Crankshaft are Reused
1. Measure the inside diameter of the cylinder block main bearings housing and the outside diameter of thecrankshaft journal.
2. Apply measurement in above step 1 to "Main Bearings Selection Table".
3. The following steps are same as in “When New Cylinder Block and Crankshaft are Used”. Refer to EM-90,
"HOW TO SELECT MAIN BEARING" .
UndersizeThickness
0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644)
Fillet R : 1.5 - 1.7 mm (0.059 - 0.067 in)
PBIC0111E
KBIA2495E
PBIC0110E
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Main Bearings Selection Table (No. 1 and No. 5 journal)
WBIA0608E
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Main Bearings Selection Table (No. 2, 3 and 4 journal)
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Main Bearings Grade Table (All Journals)
Unit: mm (in)
Use Undersize Bearing Usage Guide
Use undersize (US) bearing when the oil clearance with standard size main bearing is not within specifica-
tion.
When using undersize (US) bearing, measure the inside diameter of the bearing installed and grind the
journal until the oil clearance falls within specification.
Bearing undersize table
Unit: mm (in)
CAUTION:
Do not damage fillet R when grinding crankshaft journal in
order to use undersized bearing (All journals).
Grade number UPR/LWRThickness Identification color Remarks
0 —2.483 - 2.486 (0.0978 - 0.0979) Black
Grade is the same for upper
and lower bearings.
1
—2.486 - 2.489 (0.0979 - 0.0980) Brown
2 —2.489 - 2.492 (0.0980 - 0.0981) Green
3 —2.492 - 2.495 (0.0981 - 0.0982) Yellow
4 —2.495 - 2.498 (0.0982 - 0.0983) Blue
5 —2.498 - 2.501 (0.0983 - 0.0985) Pink
6 —2.501 - 2.504 (0.0985 - 0.0986) Purple
7 —2.504 - 2.507 (0.0986 - 0.0987) White
8 —2.507 - 2.510 (0.0987 - 0.0988) Red
01 UPR
2.483 - 2.486 (0.0978 - 0.0979) Black
Grade and color are different
for upper and lower bearings.
LWR
2.486 - 2.489 (0.0979 - 0.0980) Brown
12 UPR
2.486 - 2.489 (0.0979 - 0.0980) Brown
LWR 2.489 - 2.492 (0.0980 - 0.0981) Green
23 UPR
2.489 - 2.492 (0.0980 - 0.0981) Green
LWR 2.492 - 2.495 (0.0981 - 0.0982) Yellow
34 UPR
2.492 - 2.495 (0.0981 - 0.0982) Yellow
LWR 2.495 - 2.498 (0.0982 - 0.0983) Blue
45 UPR
2.495 - 2.498 (0.0982 - 0.0983) Blue
LWR 2.498 - 2.501 (0.0983 - 0.0985) Pink
56 UPR
2.498 - 2.501 (0.0983 - 0.0985) Pink
LWR 2.501 - 2.504 (0.0985 - 0.0986) Purple
67 UPR
2.501 - 2.504 (0.0985 - 0.0986) Purple
LWR 2.504 - 2.507 (0.0986 - 0.0987) White
78 UPR
2.504 - 2.507 (0.0986 - 0.0987) White
LWR 2.507 - 2.510 (0.0987 - 0.0988) Red
UndersizeThickness
0.25 (0.0098) 2.618 - 2.626 (0.1031 - 0.1034)
Fillet R : 1.5 - 1.7 mm (0.059 - 0.067 in)
PBIC0111E