DISASSEMBLY — Part 3 Lexus LS IV

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1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.55 mm (0.0059 to 0.0217 in.) Maximum thrust clearance: 0.70 mm (0.0276 in.) If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary. If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE Check that the front mark on the connecting rod and cap are aligned to ensure the correct reassembly. Remove the 2 connecting rod cap bolts. 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. Clean the crank pin and bearing. NOTE: Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. Check that the front mark of the connecting rod cap is facing forward. Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE: Do not turn the crankshaft. Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts by 90° as shown. Check that the painted marks are now at a 90° angle to the front. NOTE: Do not turn the crankshaft. Remove the 2 connecting rod cap bolts. 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. Measure the Plastigage at its widest point. Standard oil clearance: 0.025 to 0.050 mm (0.0010 to 0.0020 in.) Maximum oil clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface. Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin. Example: Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3") Reference: Standard sized bearing center wall thickness STANDARD SIZED BEARING CENTER WALL THICKNESS REFERENCE CHART Mark Thickness 2 1.489 to 1.492 mm (0.0586 to 0.0587 in.) 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) 4 1.495 to 1.498 mm (0.0589 to 0.0590 in.) 5 1.498 to 1.501 mm (0.0590 to 0.0591 in.) 6 1.501 to 1.504 mm (0.0591 to 0.0592 in.) 7 1.504 to 1.507 mm (0.0592 to 0.0593 in.) Connecting rod big end inside diameter CONNECTING ROD BIG END INSIDE DIAMETER REFERENCE CHART Mark Thickness 1 56.000 to 56.006 mm (2.2047 to 2.2050 in.) 2 56.007 to 56.012 mm (2.2050 to 2.2052 in.) 3 56.013 to 56.018 mm (2.2052 to 2.2054 in.) 4 56.019 to 56.024 mm (2.2055 to 2.2057 in.) Crankshaft pin diameter CRANKSHAFT PIN DIAMETER REFERENCE CHART Mark Thickness 1 52.995 to 53.000 mm (2.0864 to 2.0866 in.) 2 52.989 to 52.994 mm (2.0862 to 2.0864 in.) 3 52.982 to 52.998 mm (2.0859 to 2.0865 in.) Completely remove the Plastigage. Perform the inspection above for each cylinder.
3. REMOVE PISTON AND CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Remove the 16 cap bolts and 8 connecting rod caps. Push the 8 pistons, 8 connecting rods and 8 upper bearings through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod in the correct order.
4. REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rods and connecting rod caps. HINT: Arrange the removed parts in the correct order.
5. INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 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. Standard thrust washer thickness: 2.44 to 2.49 mm (0.0961 to 0.0980 in.)
6. REMOVE CRANKSHAFT Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown the illustration. Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration. Using a screwdriver, pry out the main bearing caps. Remove the 5 main bearing caps and lower bearings. HINT: Tape the screwdriver tip before use. NOTE: Pry up the main cap little by little to the right and left in turns. Be careful not to damage the joint surface of the cylinder block and main bearing caps. Remove the crankshaft.
7. REMOVE CRANKSHAFT BEARING Remove the crankshaft bearings from the bearing caps and cylinder block. HINT: Arrange the removed parts in the correct order.
8. REMOVE CRANKSHAFT THRUST WASHER SET Remove the thrust washer set from the cylinder block and No. 3 bearing cap.
9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.
10. REMOVE PISTON RING SET HINT: Arrange the piston rings in the correct order. Using a piston ring expander, remove the 2 compression rings. Using a piston ring expander, remove the oil ring. Remove the oil ring expander by hand.
11. REMOVE PISTON WITH PIN SUB-ASSEMBLY Disconnect the connecting rod from the piston. Using a screwdriver, pry off the snap rings from the piston. Gradually heat the piston to approximately 80°C (176°F). Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Clean piston Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
12. REMOVE STUD BOLT NOTE: If the stud bolt is deformed or its threads are damaged, replace it.

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1. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. If stuck, replace the oil nozzle. While covering A, apply air into B. Then check the oil nozzle for damage or clogging. If there is an air leak, clean or replace the oil nozzle. HINT: Cover B and apply air into A. Perform the check again. Push the check valve while covering A, and apply air into B. Check that air passes through the oil nozzle. If air cannot pass through, clean or replace the oil nozzle. HINT: Cover B and, while pushing the check valve, apply air into A. Perform the check again.
2. 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 (0.0028 in.) If the warpage is greater than the maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 8 cylinders. If necessary, replace the cylinder block.
3. 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 3.77013 in.) Maximum diameter: 94.200 mm (3.7087 in.) If the diameter is greater than the maximum, replace the cylinder block.
4. INSPECT PISTON SUB-ASSEMBLY WITH PIN Using a micrometer, measure the piston diameter at a position that is 10.7 mm (0.421 in.) downward from the center of the piston pin hole (refer to the illustration below). Standard diameter: 93.955 to 93.965 mm (3.6990 to 3.6994 in.) Maximum diameter: 93.830 mm (3.6941 in.)
5. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust direction. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.035 to 0.057 mm (0.0014 to 0.0022 in.) Maximum oil clearance: 0.370 mm (0.0146 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
6. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Standard ring groove clearance STANDARD RING GROOVE CLEARANCE REFERENCE CHART Item Specified Condition No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil 0.020 to 0.070 mm (0.0008 to 0.0028 in.) If the clearance is not as specified, replace the piston.
7. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.362 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap STANDARD END GAP REFERENCE CHART Item Specified Condition No. 1 0.23 to 0.33 mm (0.0091 to 0.0130 in.) No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.) Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum end gap MAXIMUM END GAP REFERENCE CHART Item Specified Condition No. 1 0.40 mm (0.0157 in.) No. 2 0.50 mm (0.0197 in.) Oil 0.45 mm (0.0177 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.
8. INSPECT PISTON PIN OIL CLEARANCE Check each mark on the piston, piston pin and connecting rod. Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard piston pin hole inside diameter STANDARD PISTON PIN HOLE INSIDE DIAMETER REFERENCE CHART Mark Specified Condition A 21.998 to 22.001 mm (0.8661 to 0.8662 in.) B 22.002 to 22.004 mm (0.8662 to 0.8663 in.) C 22.005 to 22.007 mm (0.8663 to 0.8664 in.) Using a micrometer, measure the piston pin diameter. Standard piston pin diameter STANDARD PISTON PIN DIAMETER REFERENCE CHART Mark Specified Condition A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) C 22.004 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: -0.002 to 0.004 mm (-0.0001 to 0.0002 in.) Maximum oil clearance: 0.015 mm (0.0006 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 bush. Standard bush inside diameter STANDARD BUSH INSIDE DIAMETER REFERENCE CHART Mark Specified Condition A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) Subtract the piston pin diameter measurement from the bush inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.03 mm (0.0012 in.) If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the connecting rod and piston pin as a set.
9. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.937 in.) If the bend is greater than the maximum, replace the connecting rod. Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.937 in.) If the twist is greater than the maximum, replace the connecting rod.
10. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter: 8.3 mm (0.327 in.) If the diameter is less than the minimum, replace the bolt.
11. INSPECT CRANKSHAFT Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle 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: 66.988 to 67.000 mm (2.6373 to 2.6378 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 (0.0008 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. Standard crank pin diameter: 52.982 to 53.000 mm (2.0859 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 (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft.
12. INSPECT CRANKSHAFT OIL CLEARANCE Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown the illustration. Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration. Using a screwdriver, pry out the main bearing caps. Remove the 5 main bearing caps and lower bearings. HINT: Tape the screwdriver tip before use. NOTE: Pry up the main cap little by little to the right and left in turns. Be careful not to damage the joint surface of the cylinder block and main bearing caps. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. HINT: If the journal or bearing is damaged, replace the bearing. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Examine the front marks and numbers, and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Place the crankshaft bearing cap on the cylinder block. Temporarily install the 10 main bearing cap bolts to the inside positions. Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length: 91 mm (3.583 in.) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts. Temporarily install the 10 main bearing cap bolts to the outside positions. Bolt length: 79.5 mm (3.130 in.) HINT: The main bearing cap bolts are tightened in 2 progressive steps. Step 1: Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) for inside position 27 N*m (275 kgf*cm, 20 ft.*lbf) for outside position If any of the main bearing cap bolts does not meet the specified torque, replace it. NOTE: Do not turn the crankshaft. Step 2: Mark the front of the bearing cap bolts with paint. Tighten the bearing cap bolts another 90° in the order shown in step 1 . Check that the painted marks are now at a 90° angle to the front. Install and uniformly tighten the 10 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) Remove the 30 bolts and bearing caps. Measure the plastigage at its widest point. Standard oil clearance STANDARD OIL CLEARANCE REFERENCE CHART Number Mark Specified Condition No. 1 and No. 5 Journal 0.017 to 0.030 mm (0.0007 to 0.0012 in.) Other journal 0.024 to 0.037 mm (0.0009 to 0.0015 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE REFERENCE CHART Number Mark Specified Condition No. 1 and No. 5 journal 0.050 mm (0.0020 in.) Other journal 0.060 mm (0.0024 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: 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 and crankshaft. Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For other position bearings, use bearing marked 3, 4, 5, 6, 7 and 8. Example: Cylinder block "07" + Crankshaft "06" = Total number 13 (Use upper bearing "6" and lower bearing "7") Standard crankshaft main journal diameter STANDARD CRANKSHAFT MAIN JOURNAL DIAMETER REFERENCE CHART Number Mark Specified Condition 00 66.999 to 67.000 mm (2.63776 to 2.63780 in.) 01 66.998 to 66.999 mm (2.63772 to 2.63776 in.) 02 66.997 to 66.998 mm (2.63768 to 2.63772 in.) 03 66.996 to 66.997 mm (2.63764 to 2.63768 in.) 04 66.995 to 66.996 mm (2.63760 to 2.63764 in.) 05 66.994 to 66.995 mm (2.63756 to 2.63760 in.) 06 66.993 to 66.994 mm (2.63752 to 2.63756 in.) 07 66.992 to 66.993 mm (2.63748 to 2.63752 in.) 08 66.991 to 66.992 mm (2.63744 to 2.63748 in.) 09 66.990 to 66.991 mm (2.63740 to 2.63744 in.) 10 66.989 to 66.990 mm (2.63736 to 2.63740 in.) 11 66.988 to 66.989 mm (2.63736 to 2.63736 in.) Standard bearing center wall thickness No. 1 and No. 5 journal STANDARD BEARING CENTER WALL THICKNESS NO. 1 AND NO. 5 JOURNAL REFERENCE CHART + (B) Upper bearing Lower bearing Number Mark Specified condition Number Mark Specified condition 00 to 02 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 03 to 05 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 5 2.488 to 2.491 (0.0988 to 0.0981 in.) 06 to 08 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 09 to 11 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 12 to 14 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 15 to 17 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 18 to 20 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 21 to 23 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 24 to 26 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 9 2.500 to 2.503 (0.0984 to 0.0985 in.) 27 to 28 9 2.516 to 2.519 (0.0991 to 0.0992 in.) 9 2.500 to 2.503 (0.0984 to 0.0985 in.) Standard bearing center wall thickness other journal STANDARD BEARING CENTER WALL THICKNESS OTHER JOURNAL REFERENCE CHART (A) + (B) Upper bearing Lower bearing Number Mark Specified condition Number Mark Specified condition 00 to 02 3 2.482 to 2.485 (0.0977 to 0.0978 in.) 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 03 to 05 4 2.485 to 2.488 (0.0978 to 0.0980 in.) 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 06 to 08 4 2.485 to 2.488 (0.0978 to 0.0980 in.) 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 09 to 11 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 12 to 14 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 15 to 17 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 18 to 20 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 21 to 23 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 24 to 26 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 27 to 28 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 8 2.513 to 2.516 (0.0989 to 0.0991 in.) Completely remove the Plastigage.
13. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point. Standard diameter: 10.8 to 11.0 mm (0.425 to 0.433 in.) for bolt A 9.8 to 10.0 mm (0.386 to 0.394 in.) for bolt B Minimum diameter: 10.7 mm (0.421 in.) for bolt A 9.7 mm (0.382 in.) for bolt B Measuring point: 47 mm (1.850 in.) If the diameter is less than the minimum, replace the bolt.

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1. REPLACE STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Remove the straight pins. Using a plastic-faced hammer, tap in new straight pins to the cylinder block. Standard protrusion STANDARD PROTRUSION REFERENCE CHART Item Specified Condition Pin A 23 mm (0.9055 in.) Pin B 11 mm (0.4331 in.) Pin C 9 mm (0.3543 in.) Pin D 6 mm (0.2362 in.)

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1. INSTALL STUD BOLT NOTE: If a stud bolt is deformed or the threads are damaged, replace it. Using an E8 "TORX" socket wrench, install the stud bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for stud bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) for stud bolt B
2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY Using a screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the service hole of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin and connecting rod with engine oil. Align the front marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the snap ring. Front mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 Piston 1 Bank 2 Piston 2 NOTE: For bank 1, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For bank 2, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides. HINT: The piston and pin are a matched set. Move the connecting rod back and forth on the piston pin. Check the fitting condition. Rotate the piston back and forth on the piston pin. Check the fitting condition. Using a screwdriver, install a new snap ring at the other end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET Install the oil ring expander by hand. Using a piston ring expander, install the oil ring as shown the illustration. Using a piston ring expander, install the 2 compression rings so that the code marks are positioned as shown in the illustration. HINT: Install the No. 1 compression ring with the code mark (1N) facing upward. Install the No. 2 compression ring with the code mark (2N) facing upward.
5. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearing. Install the upper bearing. NOTE: Main bearings come in widths of 21 mm (0.8268 in.) and 22.5 mm (0.8858 in.). Install the 22.5 mm (0.8858 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.8268 in.) bearings in the No. 2, No. 3 and No. 4 positions. Install the upper bearing to the cylinder block as shown in the illustration. NOTE: Do not apply engine oil to the bearings and the contact surface. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one. Install the lower bearing. NOTE: Be sure to install the selected bearing. Main bearings come in widths of 21 mm (0.8268 in.) and 22.5 mm (0.8858 in.). Install the 22.5 mm (0.8858 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.8268 in.) bearings in the No. 2, No. 3 and No. 4 positions. Install the lower bearings to the bearing caps. Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge. Dimension A - B or B - A: 0 to 0.7 mm (0 to 0.028 in.) NOTE: Do not apply engine oil to the bearings and the contact surface. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
6. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the thrust washer set. Install the 4 thrust washers to the No. 3 journal position of the cylinder block and bearing cap with the oil grooves facing outward.
7. INSTALL CRANKSHAFT Apply engine oil to the upper bearing and lower bearing, then place the crankshaft on the cylinder block. Confirm the front marks and numbers of the main bearing caps, and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Temporarily install the 10 main bearing cap bolts to the inside positions. Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length: 91 mm (3.583 in.) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts. Temporarily install the 10 main bearing cap bolts to the outside positions. Bolt length: 79.5 mm (3.130 in.) HINT: The main bearing cap bolts are tightened in 2 progressive steps. Step 1: Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) for inside position 27 N*m (275 kgf*cm, 20 ft.*lbf) for outside position If any of the main bearing cap bolts does not meet the specified torque, replace it. Step 2: Mark the front of the bearing cap bolts with paint. Tighten the bearing cap bolts another 90° in the order shown in step 1 . Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly. Install and uniformly tighten the 10 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) Check that the crankshaft turns smoothly.
8. INSTALL CONNECTING ROD BEARING Install the connecting rod bearing to the connecting rod and bearing cap. Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge. Dimension A - B or B - A: 0 to 0.7 mm (0 to 0.028 in.) NOTE: Do not apply engine oil to the bearings and the contact surface. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
9. INSTALL PISTON AND 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. NOTE: Do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward. NOTE: Match the numbered connecting rod cap with the connecting rod. Front mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 1 Bank 2 2 Check that the front mark of the connecting rod cap is facing forward. Front mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 Front Side Bank 2 Rear Side Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Temporarily install the connecting cap bolts. HINT: The connecting 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: 40 N*m (408 kgf*cm, 30 ft.*lbf) Step 2: Mark the front side of each connecting cap bolt with paint. Tighten the cap bolts another 90° as shown in the illustration in the order in step 1 . Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

1. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-349724-S31319866602009120800000) )
2. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY (See «REMOVAL»(ref-349724-S31319866602009120800000) )
3. REMOVE NO. 1 AIR CLEANER INLET (See «REMOVAL»(ref-349724-S31319866602009120800000) )
4. REMOVE INTAKE AIR CONNECTOR PIPE (See «REMOVAL»(ref-349724-S31319866602009120800000) )
5. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-349714-S30226729992009120800000) )
6. REMOVE RESONATOR BRACKET SUB-ASSEMBLY Remove the bolt and resonator bracket.
7. REMOVE CRANKSHAFT PULLEY (See «REMOVAL»(ref-349714-S26196101182009120800000) )
8. REMOVE CRANKSHAFT TIMING GEAR KEY Remove the crankshaft timing gear key from the crankshaft.
9. REMOVE TIMING CHAIN CASE OIL SEAL Remove the oil seal with a screwdriver. HINT: Tape the screwdriver tip before use. NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft.
10. INSTALL TIMING CHAIN CASE OIL SEAL Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge. SST 09223-22010, 09506-35010 NOTE: Keep the lip free from foreign matter. Do not tap oil seal at an angle.
11. INSTALL CRANKSHAFT TIMING GEAR KEY Install the crankshaft timing gear key.
12. INSTALL CRANKSHAFT PULLEY (See «INSTALLATION»(ref-349714-S38774077922009120800000) )
13. INSTALL RESONATOR BRACKET SUB-ASSEMBLY Install the resonator bracket with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
14. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-349714-S35834705202009120800000) )
15. INSTALL INTAKE AIR CONNECTOR PIPE (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
16. INSTALL NO. 1 AIR CLEANER INLET (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
17. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
18. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349724-S09859827162009120800000) )

Scheme 612

Scheme 613

Scheme 614

1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY Remove the automatic transmission (See «REMOVAL»(ref-349712-S35304403202009120800000) ).
4. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «REMOVAL»(ref-349714-S31912998822009120800000) )
5. REMOVE ENGINE REAR OIL SEAL Remove the oil seal with a screwdriver. HINT: Tape the screwdriver tip before use. NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft.
6. INSTALL ENGINE REAR OIL SEAL Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07150) NOTE: Keep the lip free from foreign matter. Do not tap on the oil seal at an angle.
7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
8. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Install the automatic transmission (See «INSTALLATION»(ref-349712-S11836634372009120800000) ).
9. PERFORM INITIALIZATION Preform initialization (See «INITIALIZATION»(ref-349706-S07943075812009120800000) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

Scheme 615