Engine Mechanical (Service Information): Overhaul Lexus ES XV60

REASSEMBLY [06/2012 - ]

HINT

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION [06/2012 - ] .

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1. INSTALL SPARK PLUG TUBE HINT: When using a new cylinder head sub-assembly, the spark plug tubes must be replaced. Apply adhesive onto the shaded area of a new spark plug tube. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard application width 1.0 to 3.0 mm (0.0394 to 0.118 in.) NOTE: Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to engine oil for at least 1 hour after installing it. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height. TEXT IN ILLUSTRATION *a Cylinder Head Top Surface Standard protrusion height 72.9 mm (2.87 in.) NOTE: To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.
2. INSTALL NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs. TEXT IN ILLUSTRATION *a Bank 1 *b Bank 2 Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
3. INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs. TEXT IN ILLUSTRATION *a Bank 1 *b Bank 2 Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
4. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head sub-assembly.
5. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new valve stem oil seals. TEXT IN ILLUSTRATION *a Gray (Intake Side) *b Black (Exhaust Side) NOTE: Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later. HINT: The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black. Using SST, push in the valve stem oil seals. TEXT IN ILLUSTRATION *a Correct *b Incorrect SST: 09201-41020 NOTE: Failure to use SST will cause the valve stem seal to be damaged or improperly seated.
6. INSTALL EXHAUST VALVE Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly. NOTE: Install the same parts in the same combination to the original locations. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
7. INSTALL INTAKE VALVE Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the intake valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly. NOTE: Install the same parts in the same combination to their original locations. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
8. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the valve stem caps on the valves.

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1. REPAIR INTAKE VALVE SEAT NOTE: Repair the intake valve seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the intake valve seat so that the intake valve seat width is greater than the specification. Using 30° and 60° cutters, correct the intake valve seat so that the intake valve contacts the entire circumference of the intake valve seat. The contact should be in the center of the intake valve seat, and the intake valve seat width should be maintained within the specified range around the entire circumference of the intake valve seat. TEXT IN ILLUSTRATION *a Width Width 1.1 to 1.5 mm (0.0433 to 0.0591 in.) Handrub the intake valve and intake valve seat with an abrasive compound. Check the intake valve seating position.
2. REPAIR EXHAUST VALVE SEAT NOTE: Repair the exhaust valve seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the exhaust valve seat so that the exhaust valve seat width is greater than the specification. Using 30° and 75° cutters, correct the exhaust valve seat so that the exhaust valve contacts the entire circumference of the exhaust valve seat. The contact should be in the center of the exhaust valve seat, and the exhaust valve seat width should be maintained within the specified range around the entire circumference of the exhaust valve seat. TEXT IN ILLUSTRATION *a Width Width 1.1 to 1.5 mm (0.0433 to 0.0591 in.) Hand lap the exhaust valve and exhaust valve seat with an abrasive compound. Check the exhaust valve seating position.

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1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned. HINT: The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for the correct reassembly. Remove the 2 connecting rod cap bolts. TEXT IN ILLUSTRATION Engine Front Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Using a ridge reamer, remove all the carbon from the top of the cylinder. TEXT IN ILLUSTRATION *1 Ridge Reamer Push the piston, connecting rod sub-assembly and upper bearing through the top of the cylinder block sub-assembly. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
2. REMOVE CONNECTING ROD BEARING HINT: Arrange the removed parts in the correct order.
3. REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. TEXT IN ILLUSTRATION *1 Piston Ring Expander Remove the oil ring expander and 2 side rails by hand. HINT: Arrange the removed parts in the correct order.
4. REMOVE PISTON Check the fitting condition between the piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. Disconnect the connecting rod from the piston. Using a screwdriver, pry off the piston pin hole snap rings from the piston. Gradually heat the piston to approximately 80°C (176°F). Using a brass bar and a plastic hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly. HINT: The piston and piston pin are a matched set. Arrange the pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in the correct order. Using a gasket scraper, remove the carbon from the piston top. NOTE: Be careful not to scratch a piston. Using a groove cleaning tool, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
5. REMOVE CRANKSHAFT Uniformly loosen and remove the 8 crankshaft bearing cap bolts and the 8 seal washers in several steps and in the sequence shown in the illustration. Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration. Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cylinder Block Sub-Assembly *3 Bearing Cap *a Joint Surface NOTE: Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed. Be careful not to damage the joint surface of the cylinder block sub-assembly and the crankshaft bearing cap. Remove the crankshaft.
6. REMOVE CRANKSHAFT BEARING Remove the upper crankshaft bearings and lower crankshaft bearings. HINT: Arrange the removed parts in the correct order.
7. REMOVE CRANKSHAFT THRUST WASHER SET Remove the 2 crankshaft thrust washers from the cylinder block sub-assembly.
8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging. If necessary, replace the No. 1 oil nozzle sub-assembly.
9. CLEAN CYLINDER BLOCK

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1. INSPECT CONNECTING ROD THRUST CLEARANCE Install the connecting rod cap See step 8 . Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.15 to 0.40 mm (0.00591 to 0.0157 in.) Maximum thrust clearance 0.50 mm (0.0197 in.) If the thrust clearance is greater than the maximum, replace the connecting rod sub-assembly. If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. TEXT IN ILLUSTRATION *1 Plastigage Ensure that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *a Front Mark Engine Front Install the connecting rod cap See step 8 . NOTE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap See step 1 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *a Mark 1, 2, 3, or 4 Standard oil clearance 0.045 to 0.067 mm (0.00177 to 0.00264 in.) Maximum oil clearance 0.070 mm (0.00276 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing standard thickness is indicated by a number (1, 2, 3 or 4) marked on its surface. Connecting Rod Diameter Mark Diameter 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.) 2 56.007 to 56.012 mm (2.20500 to 2.20519 in.) 3 56.013 to 56.018 mm (2.20523 to 2.20543 in.) 4 56.019 to 56.024 mm (2.20547 to 2.20566 in.) Connecting Rod Bearing Center Wall Thickness Mark Thickness 1 1.481 to 1.484 mm (0.05831 to 0.05843 in.) 2 1.484 to 1.487 mm (0.05843 to 0.05854 in.) 3 1.487 to 1.490 mm (0.05854 to 0.05866 in.) 4 1.490 to 1.493 mm (0.05866 to 0.05878 in.) Standard crankshaft pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) NOTE: Completely remove the Plastigage after the measurement.
3. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Maximum warpage 0.07 mm (0.00276 in.) If the warpage is greater than the maximum, replace the cylinder block sub-assembly.
4. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter 94.13 mm (3.7059 in.) TEXT IN ILLUSTRATION *a Thrust Direction *b Axial Direction *c 10 mm (0.394 in.) *d Center Front If the average diameter of 4 positions is greater than the maximum, replace the cylinder block sub-assembly.
5. INSPECT PISTON Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified. Distance 8.9 mm (0.3504 in.) Standard diameter 93.960 to 93.980 mm (3.6992 to 3.7000 in.) Minimum diameter 93.830 mm (3.6941 in.) TEXT IN ILLUSTRATION *a Distance If the piston diameter is less than the minimum, replace the piston and piston pin as a set.
6. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust directions. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.020 to 0.052 mm (0.000787 to 0.00205 in.) Maximum oil clearance 0.060 mm (0.00236 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly.
7. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring Groove Clearance Item Clearance No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in.) No. 2 0.020 to 0.060 mm (0.000787 to 0.00236 in.) Oil 0.070 to 0.150 mm (0.00276 to 0.00591 in.) If the clearance is not as specified, replace the piston.
8. INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston Pin Hole Inside Diameter Mark Diameter A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) B 22.004 to 22.007 mm (0.8663 to 0.8664 in.) C 22.007 to 22.010 mm (0.8664 to 0.8665 in.) Using a micrometer, measure the piston pin diameter. Piston Pin Diameter Mark Diameter A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.000 to 22.003 mm (0.8661 to 0.8663 in.) C 22.003 to 22.006 mm (0.8663 to 0.8664 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.015 mm (0.000591 in.) If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing Inside Diameter Mark Diameter A 22.005 to 22.008 mm (0.86634 to 0.86645 in.) B 22.009 to 22.011 mm (0.86649 to 0.86657 in.) C 22.012 to 22.014 mm (0.86661 to 0.86669 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. TEXT IN ILLUSTRATION *a Front Mark *b Piston Pin Hole Inside Diameter Mark *c Connecting Rod Bushing Inside Diameter Mark Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance 0.030 mm (0.00118 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.
9. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly. TEXT IN ILLUSTRATION *1 Piston Ring Using a feeler gauge, measure the end gap. Standard End Gap Item End Gap No. 1 0.22 to 0.32 mm (0.00866 to 0.0126 in.) No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.) Oil 0.10 to 0.40 mm (0.00394 to 0.0157 in.) Maximum End Gap Item End Gap No. 1 0.50 mm (0.0197 in.) No. 2 0.85 mm (0.0335 in.) Oil 0.60 mm (0.0236 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block sub-assembly.
10. INSPECT CRANKSHAFT THRUST CLEARANCE Install the crankshaft bearing cap See step 6 . Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
11. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod sub-assembly alignment. Check for out-of-alignment. Maximum out-of-alignment 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod sub-assembly. Check for twist. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod sub-assembly.
12. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration. TEXT IN ILLUSTRATION *a Measurement Area Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. HINT: Diameter measurements should be done at several points. If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the connecting rod bolt with a new one.
13. INSPECT CRANKSHAFT Inspect for runout. Clean the crank journal. Place the crankshaft on V-blocks. Using a dial indicator, measure the runout at the center journal. Maximum runout 0.06 mm (0.00236 in.) If the runout is greater than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. Inspect the crank pin. Using a micrometer, measure the diameter of each crank pin. Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft.
14. INSPECT CRANKSHAFT OIL CLEARANCE Check the crank journal and crankshaft bearing for pitting and scratches. Install the crankshaft bearing See step 4 . Place the crankshaft on the cylinder block sub-assembly. Lay a strip of Plastigage across each journal. TEXT IN ILLUSTRATION *1 Plastigage Examine the front marks and numbers to install the crankshaft bearing caps on the cylinder block sub-assembly. HINT: A number is marked on each main bearing cap to indicate the installation position. Install the main bearing cap See step 6 . NOTE: Do not turn the crankshaft. Remove the main bearing caps See step 5 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage Standard oil clearance 0.026 to 0.047 mm (0.00102 to 0.00185 in.) Maximum oil clearance 0.050 mm (0.00197 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: Completely remove the Plastigage after the measurement. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block sub-assembly and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. TEXT IN ILLUSTRATION *a Number Mark *b No. 2 and No. 3 Journal Bearing *c No. 1 and No. 4 Journal Bearing JOURNAL BEARINGS Cylinder block sub-assembly+ Crankshaft 0 - 5 6 - 11 12 - 17 18 - 23 24 - 28 Bearing to be used "1" "2" "3" "4" "5" HINT: EXAMPLE: Cylinder block sub-assembly "11" + Crankshaft "06" = Total number 17 (Use bearing "3") Crankshaft Main Journal Diameter Mark Diameter "00" 60.999 to 61.000 mm (2.40153 to 2.40157 in.) "01" 60.998 to 60.999 mm (2.40149 to 2.40153 in.) "02" 60.997 to 60.998 mm (2.40145 to 2.40149 in.) "03" 60.996 to 60.997 mm (2.40141 to 2.40145 in.) "04" 60.995 to 60.996 mm (2.40137 to 2.40141 in.) "05" 60.994 to 60.995 mm (2.40133 to 2.40137 in.) "06" 60.993 to 60.994 mm (2.40129 to 2.40133 in.) "07" 60.992 to 60.993 mm (2.40126 to 2.40129 in.) "08" 60.991 to 60.992 mm (2.40122 to 2.40126 in.) "09" 60.990 to 60.991 mm (2.40118 to 2.40122 in.) "10" 60.989 to 60.990 mm (2.40114 to 2.40118 in.) "11" 60.988 to 60.989 mm (2.40110 to 2.40114 in.) Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Thickness "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.) "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.) "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.) "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.) "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.) Standard Lower Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.) "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.) "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.) "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.) "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.) Standard Upper Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.) "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.) "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.) "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.) "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.) Standard Lower Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Thickness "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.) "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.) "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.) "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.) "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.)
15. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the diameter of the threads at the measurement point. TEXT IN ILLUSTRATION *a Measurement Point Standard diameter 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Minimum diameter 10.7 mm (0.4213 in.) Measurement Point 40 mm (1.57 in.) HINT: If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.
16. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Check the No. 1 oil nozzles sub-assembly for damage or clogs. HINT: If there is damage or clogs, replace the No. 1 oil nozzles sub-assembly.

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1. REPLACE STRAIGHT PIN Using a plastic hammer, tap in new straight pins to the cylinder block sub-assembly. TEXT IN ILLUSTRATION *a Front Side *b Rear Side *c Upper Side *d Lower Side *e RH Side - - Standard Protrusion Item Protrusion Pin A 23 mm (0.906 in.) Pin B 6 mm (0.236 in.) Pin C 11 mm (0.433 in.) Pin D 9 mm (0.354 in.)
2. REPLACE STUD BOLT Using an E8 and E10 "TORX" socket wrench, install the stud bolts. TEXT IN ILLUSTRATION *a Front Side *b LH Side Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)

HINT

Perform "Inspection After Repair" after replacing the piston and piston ring. Refer to INITIALIZATION [06/2012 - ] .

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1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 3 No. 1 oil nozzle sub-assemblies with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL PISTON Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Hole HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb. TEXT IN ILLUSTRATION *a Front Mark HINT: The piston and pin are a matched set. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Hole HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Perform "Inspection After Repair" after replacing the piston. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
3. INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the compression ring as shown in the illustration. TEXT IN ILLUSTRATION *1 Piston Ring Expander *2 Upper Side Rail *3 Oil Ring Expander *4 Lower Side Rail *5 Oil Ring *6 No. 1 Ring *7 No. 2 Ring Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 Lower Side Rail *2 No. 2 Ring *3 Oil Ring Expander *4 No. 1 Ring *5 Upper Side Rail *a Front Mark NOTE: Do not align the ring ends. HINT: Perform "Inspection After Repair" after replacing the piston ring. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
4. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the crankshaft bearings. TEXT IN ILLUSTRATION *1 No. 1 and No. 4 Journal Bearing *2 No. 2 and No. 3 Journal Bearing NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) crankshaft bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) crankshaft bearings in the No. 2 and No. 3 positions. Install the upper crankshaft bearing. Install the upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration. TEXT IN ILLUSTRATION *1 Upper Bearing *a Correct *b Incorrect NOTE: Do not apply engine oil to the crankshaft bearings and the contact surfaces. Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal. Install the lower crankshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper *a Mark 1, 2, 3, 4 or 5 Install the lower crankshaft bearings to the crankshaft bearing caps. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge. Dimension (A - B) 0.7 mm (0.0276 in.) or less NOTE: Do not apply engine oil to the crankshaft bearings and the contact surfaces.
5. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the crankshaft thrust washers. Install the 2 crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward. TEXT IN ILLUSTRATION *1 Oil Grooves
6. INSTALL CRANKSHAFT Apply engine oil to the crankshaft bearings, then place the crankshaft on the cylinder block sub-assembly. Confirm the projections and numbers on the crankshaft bearing caps and install the crankshaft bearing caps on the cylinder block sub-assembly. TEXT IN ILLUSTRATION *1 Projection *a Number Mark HINT: A number is marked on each crankshaft bearing cap to indicate the installation position. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions. Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block sub-assembly is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide. TEXT IN ILLUSTRATION *a Less than 6 mm *b Bolt Length 100 to 102 mm Bolt length 100 to 102 mm (3.94 to 4.02 in.) Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts. Install the 8 crankshaft bearing cap bolts to the outside positions. TEXT IN ILLUSTRATION *a Bolt Length Bolt length 105.5 to 107.5 mm (4.15 to 4.23 in.) Install the crankshaft bearing cap bolts. HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps. Step 1 Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it. Step 2 TEXT IN ILLUSTRATION *a Paint Mark *b Turn 90° Engine Front Mark the front of the crankshaft bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the sequence shown in the illustration. Check that the painted mark is now at a 90° angle to the front of the engine. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Bolt Length Item Length Bolt A 45 mm (1.77 in.) Except bolt A 30 mm (1.18 in.) Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance See step 10 .
7. INSTALL CONNECTING ROD BEARING Install the connecting rod bearing to the connecting rod sub-assembly and connecting rod cap. Using a vernier caliper, measure the distance between the connecting rod sub-assembly and connecting rod cap edges and the connecting rod bearing edge. TEXT IN ILLUSTRATION *1 Vernier Caliper Dimension (A - B) 0.7 mm (0.0276 in.) or less NOTE: Do not apply engine oil to the connecting rod bearings and the contact surfaces.
8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 Lower Side Rail *2 No. 2 Ring *3 Oil Ring Expander *4 No. 1 Ring *5 Upper Side Rail *a Front Mark NOTE: Do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing forward. TEXT IN ILLUSTRATION *a Front Mark Engine Front NOTE: Match the numbered connecting rod cap with the connecting rod sub-assembly. Check that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *a Front Mark Engine Front Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Install the connecting rod cap bolts. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) Step 2 TEXT IN ILLUSTRATION *a Paint Mark *b Turn 90° Engine Front Mark the front side of each connecting rod cap bolt with paint. Retighten the cap bolts 90° as shown in the illustration. Check that the painted mark is now at a 90° angle to the front. Confirm that the crankshaft turns smoothly. Check the connecting rod thrust clearance See step 1 .