CYLINDER BLOCK
EM-113
< DISASSEMBLY AND ASSEMBLY >
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2. Install each plug to cylinder block as shown in the figure.
Apply sealant to the thread of water drain plug (A).
Use Genuine Liquid Gasket or equivalent.
Apply sealant to the thread of connector bolt (D).
Use Genuine Liquid Gasket or equivalent.
Apply sealant to the thread of plug (C).
Use high strength thread locking sealant or equivalent.
Replace washers with new one.
Tighten each plug and connector bolt as specified below.
3. Install oil jet. (VQ35DE)
Insert oil jet dowel pin (A) into cylinder block dowel pin hole,
and tighten mounting bolts.
4. Install main bearings and thrust bearings as follows:
CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
B : Water drain plug
PBIC2487E
Part Washer Tightening torque
A Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
B No 9.8 N·m (1.0 kg-m, 87 in-lb)
C Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
D No 39.2 N·m (4.0 kg-m, 29 ft-lb)
: Engine front
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EM-114
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
b. Install thrust bearings (1) to the both sides of the No. 3 journal
housing on cylinder block and main bearing cap.
Install thrust bearings with the oil groove (E) facing crankshaft
arm (outside).
Install thrust bearing with a projection on one end on cylinder block, and thrust bearing with a projection
at center on main bearing cap. Align each projection with mating notch.
c. Install main bearings paying attention to the direction.
Main bearing with oil hole (B) and groove (C) goes on cylinder
block. The one without them goes on main bearing cap.
Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
When installing, align main bearing stopper protrusion to cut-
out of cylinder block and main bearing caps.
Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install crankshaft to cylinder block.
While turning crankshaft by hand, check that it turns smoothly.
6. Install main bearing caps.
Main bearing caps are identified by identification mark cast on
them. For installation, face front mark (E) to front side.
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
7. Install main bearing beam.
Install main bearing beam with front mark facing downward (oil pan side).
Install main bearing beam with front mark facing front of the
engine.
A : No. 1
B : No. 2
C : No. 3
D : No. 4
F : Thrust bearing installation position
: Engine front
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A : Cylinder block side
D : Main bearing cap side
: Engine front
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A : No. 1
B : No. 2
C : No. 3
D : No. 4
: Engine front
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PBIC0881E
CYLINDER BLOCK
EM-115
< DISASSEMBLY AND ASSEMBLY >
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8. Install main bearing cap bolts in numerical order as shown in the
figure as follows:
a. Inspect the outer diameter of main bearing cap bolt. Refer to
EM-119, "
Inspection".
b. Apply new engine oil to threads and seat surfaces of main bear-
ing cap bolts.
c. Tighten main bearing cap bolts in several different steps.
d. Turn all main bearing cap bolts 90 degrees clockwise (angle tightening).
CAUTION:
Use the angle wrench [SST: KV10112100 (BT8653-A)] to
check tightening angle. Never make judgment by visual
inspection.
After installing main bearing cap bolts, check that crankshaft
can be rotated smoothly by hand.
Check the crankshaft end play. Refer to EM-119, "
Inspection".
9. Install piston to connecting rod as follows:
a. Using snap ring pliers, install new snap ring to the groove of piston rear side.
Insert it fully into groove to install.
b. Install piston to connecting rod.
Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without
excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into
piston and connecting rod.
Assemble so that the front mark on the piston crown and the
cylinder number on connecting rod are positioned as shown in
the figure.
c. Install new snap ring to the groove of the piston front side.
Insert it fully into groove to install.
After installing, check that connecting rod moves smoothly.
10. Using a piston ring expander (commercial service tool) (A),
install piston rings.
CAUTION:
When installing piston rings, be careful not to damage
piston.
Be careful not to damage piston rings by expending them
excessively.
: Engine front
: 35.3 N·m (3.6 kg-m, 26 ft-lb)
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PBIC0921E
SEM838F
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EM-116
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
If there is stamped mark on ring, mount it with marked side up.
NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.
Position each ring with the gap as shown in the figure referring
to the piston front mark (D).
Check the piston rings side clearance. Refer to EM-119, "
Inspection".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
When installing, align connecting rod bearing stopper protru-
sion (B) with cutout (C) of connecting rod and connecting rod
bearing cap to install.
Ensure the oil hole (A) on connecting rod and that on the cor-
responding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft.
Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
Match the cylinder position with the cylinder number on connecting rod to install.
Be sure that front mark on piston crown is facing front of engine.
Using a piston ring compressor [SST: EM03470000 (J8037)]
(A) or suitable tool, install piston with the front mark on the pis-
ton crown facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.Stamped mark: VQ25DE VQ35DE
To p r i n g ( A ) : R : —
Second ring (B) : R 2 : 2 R
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C : Top ring gap
E : Oil ring upper or lower rail gap (either of then)
F : Second ring and oil ring spacer gap
a : 90 degrees
b : 45 degrees
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CYLINDER BLOCK
EM-117
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13. Install connecting rod bearing cap.
Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install.
Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
14. Tighten connecting rod bolt as follows:
a. Inspect the outer diameter of connecting rod bolt. Refer to EM-119, "
Inspection".
b. Apply engine oil to the threads and seats of connecting rod bolts.
c. Tighten connecting rod bolts.
d. Then tighten all connecting rod bolts 90 degrees clockwise (angle tightening).
CAUTION:
Always use the angle wrench [SST: KV10112100 (BT8653-
A)]. Avoid tightening based on visual check alone.
After tightening connecting rod bolts, check that crankshaft
rotates smoothly.
Check the connecting rod side clearance. Refer to EM-119,
"Inspection".
15. Install baffle plate to main bearing beam.
16. Install new rear oil seal retainer to cylinder block. Refer to EM-94, "
REAR OIL SEAL : Removal and Instal-
lation".
17. Install pilot converter.
With drift [outer diameter: approximately 33 mm (1.30 in)],
press-fit as far as it will go.
A: Sample codes
B : Bearing stopper groove
C : Small-end diameter grade
D : Standard stamp
E : Weight grade
F : Cylinder No.
G : Management code
I : Management code
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: 19.6 N·m (2.0 kg-m, 14 ft-lb)
SEM953E
PBIC0899E
CYLINDER BLOCK
EM-119
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Install drive plate (2) and reinforcement plate (3) as shown in
the figure.
Holding ring gear with the pulley holder (commercial service
tool).
Tighten mounting bolts crosswise over several times.
InspectionINFOID:0000000003802295
CRANKSHAFT END PLAY
Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator.
If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
CONNECTING ROD SIDE CLEARANCE
Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).
If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
Piston Pin Outer Diameter
1 : Ring gear
4 : Pilot converter
5 : Crankshaft
A : Rounded
: Engine front
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Standard and limit : Refer to EM-143, "CylinderBlock".
EMQ0196D
Standard and limit : Refer to EM-143, "CylinderBlock".
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Standard : Refer to EM-143, "CylinderBlock".
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EM-120
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer (A).
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
If the calculated value is out of the standard, replace piston and piston pin assembly.
When replacing piston and piston pin assembly, refer to EM-129, "
Description".
NOTE:
Piston is available together with piston pin as assembly.
Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)
PISTON RING SIDE CLEARANCE
Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C).
If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
PISTON RING END GAP
Check that the cylinder bore inner diameter is within the specification. Refer to EM-143, "CylinderBlock".
Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with a feeler gauge (B).
If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, rebore cylinder and use
oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION
Standard : Refer to EM-143, "CylinderBlock".
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Standard : Refer to EM-143, "CylinderBlock".
A: NG
B: OK
Standard and limit : Refer to EM-143, "CylinderBlock".
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A : Press-fit
C : Measuring point
Standard and limit : Refer to EM-143, "CylinderBlock".
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CYLINDER BLOCK
EM-123
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Unit: mm (in)
*: After installing in connecting rod
CYLINDER BLOCK DISTORTION
Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
Measure the distortion on the cylinder block upper face at some
different points in six directions (C), (D), (E), (F), (G) and (H) with a
straightedge (A) and a feeler gauge (B).
If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
Install main bearing caps (2) and main bearing beam without
installing main bearings, and tighten main bearing cap bolts to the
specified torque. Refer to EM-110, "
Disassembly and Assembly"
for the tightening procedure.
Measure the inner diameter of main bearing housing with a bore
gauge.
If out of the standard, replace cylinder block (1) and main bearing
caps as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is
machined together with main bearing caps.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore inner Diameter
Using a bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. [(A) and (B) direc-
tions at (C), (D) and (E)] is in longitudinal direction of engine.
Grade 0 1
Connecting rod bushing inner diameter *22.000 - 22.006
(0.8661 - 0.8664)22.006 - 22.012
(0.8664 - 0.8666)
Piston pin hole diameter21.993 - 21.999
(0.8659 - 0.8661)21.999 - 22. 005
(0.8661 - 0.8663)
Piston pin outer diameter21.989 - 21.995
(0.8657 - 0.8659)21.995 - 22.001
(0.8659 - 0.8662)
Limit : Refer to EM-143, "CylinderBlock".
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Standard : Refer to EM-143, "CylinderBlock".
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f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)
Standard and limit : Refer to EM-143, "
CylinderBlock".
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