14−172

ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

GENERAL REVIEW
1. EXTRACT THE DRAIN KEY SUBASSEMBLY FROM THE CYLINDER BLOCK
2. REMOVE THE WATER SEAL PLATE
3. REMOVE THE STRAIGHT THREADED PLUG WITH HEAD NO. 1 FROM THE CYLINDER BLOCK
Remove the threaded plug with a 10 mm hexagonal tubular wrench. 1405L−06

4. REMOVE THE STRAIGHT THREADED PLUG WITH NO.2 HEAD FROM THE CYLINDER BLOCK
Remove the threaded plug with a 10 mm hex socket wrench.
5. REMOVE THE STRAIGHT SCREW PLUG WITH NO.3 HEAD FROM THE CYLINDER BLOCK
Remove the threaded plug with a 10 mm hexagonal tubular wrench.

6. VERIFICATION OF THRUST CALIBRATION

THE CONNECTING ROD

Use a quadrant indicator to measure the calibration.

of thrust while moving the connecting rod backwards and ade-
lante.
Standard thrust calibration:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust calibration: 0.35 mm (0.0138 in.)
P12695 7. CALIBRATION VERIFICATION FOR OIL
FROM THE CONNECTING ROD

(a) Check that the alignment marks on the connecting rod and the cap
be aligned in order to ensure their correct assembly.
Remove the 2 screws from the rod cover.
Clean the wrist, the bearing, and the connecting rod.
Check that the wristband and the bearing do not have pitting.
scratches and streaks.

Place a strip of Plastigage along the wrist.

Plastigage

A78793

(f) Check that the protruding part of the small hat of

Front white is oriented in the right direction.
Apply a thin layer of engine oil on the thread
of the lid rod bolts.

Outgoing

A78794
 14−173
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(h) Tighten the bolts step by step according to the specifications.

twisting songs.
Torque: 25 N⋅m (250 kgf⋅cm, 18 lbf⋅pie

P12697

(i) Mark the front part of each bolt with paint.

Painted mark
90 the small hats
Re-tighten the of thetobushing.
bolts 90_as illustrated.
90
(j)
NOTICE:
Front
Do not turn the crankshaft.
Remove the 2 bolts, the connecting rod cap, and the bearing.
inferior.

A78795

(l) Put the Plastigage strip on the widest part.

Standard calibration for oil:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum calibration for the oil: 0.08 mm (0.0031
pulg.)
NOTICE:
Remove the Plastigage strip.

P12698

If it is necessary to change the bearing, use a bearing with the same...

Brand of my number than the one marked on the connecting rod. There are four sizes
number of standard bearings, marked with '1', '2', '3' and '4'.
ADVICE:
Standard thickness of the central bearing wall
Brand mm (inches)
1 1.484 to 1.487 (0.0584 to 0.0585)
2 1.487 a 1.490 (0.0585 a 0.0587)
3 1.490 to 1.493 (0.0587 to 0.0588)
A79803
4 1.493 to 1.496 (0.0588 to 0.0589)
8. EXTRACT THE PISTON SUBASSEMBLY AND THE
WHITE
Use a cylinder rim reamer to eliminate
remove the carbon from the top of the cylinder.
Push out the piston and connecting rod assembly
the top of the cylinder block.
ADVICE:
S Together conserve the bearings, the connecting rod and the cover.
S
Arrange the piston and connecting rod assemblies in the co- order
A05258
correct.
14−174
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

9. REMOVE THE CONNECTING ROD BEARING

10. EXTRACT THE ASSEMBLY OF SEGMENTS OF

PISTON
Extract the 2 compression rings with an expander.
piston rings.
(b) Extract the two side lanes and the lubrication ring
handmade.

A78315

11. REMOVE THE RETAINING RING FROM THE HOLE

OF THE BOLT
Using a small screwdriver as a lever, remove the
2 retaining rings.

P12403

80_C (176_F) 12. EXTRACT THE SUBASSEMBLY OF THE PISTON WITH THE
Buckle heat the piston
Gradually until it reaches 80_C
approximately (176_F).

A78797

Lightly tap with a plastic head hammer

and a bronze bar the bolt and extract the connecting rod.
ADVICE:
S
The piston and the pin form an assembly.
S
Store the pistons, the bolts, the piston rings.
tone, the cranks and the bearings in the correct order in order to
reinstall them in their original place when reassembling the
sample.
P12415
 14 minus 175
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

13. CHECK THE THRUST CALIBRATION OF

CRANKSHAFT
(a) What is thrust calibration with a tail indicator?
forcing while leveraging with a screwdriver so-
brake the crankshaft.
Standard thrust calibration:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust calibration: 0.30 mm (0.0118 in.)
P12799 If the calibration is above the maximum, change the entire group of
thrust washers. Check that the crankshaft is not degassed.
repair it or replace it if necessary.
ADVICE:
The thickness of the washer is 1.93 to 1.98 mm (0.0760 to 0.0780
pulg.)

14. REMOVE THE CRANKSHAFT

5 (a) Loosen and uniformly extract the 8 bolts in stages.
8 and the washers of the main bearing caps
7
in the order illustrated.
6 2
3
4
1 A78798

Loosen and evenly extract the 16 bolts in stages.

from the caps of the main bearings in the order that
it is illustrated.
4 12
8 11
6 16 3
2 14 15
7
10 13
9 5
1 A78799
-162
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(c)Remove the caps from the main bearings by making pa-

launch with a screwdriver. Remove the 4 caps from the bearings.
main nets and the lower bearings.
NOTICE:
S
Carefully remove the lids, alternating the point of
supporting and lifting them up little by little.
S
Be careful not to damage the joint surface of the
cylinder block and the main bearing cap.
P12603

Surface of the joint

A78800

15. EXTRACT THE CRANKSHAFT THRUST WASHER ASSEMBLY

16. REMOVE THE CRANKSHAFT BEARING

17. CHECK THE LEVELING OF THE BLOCK OF

Cylinders
(a) With a precision ruler and a calibration gauge, my-
gives the deformation of the contact surface with the em-
head gasket of the cylinders.
Deformación máxima: 0.05 mm (0.0020 pulg.)
If the deformation exceeds the maximum, change the block of
cylinders.

Z09222
 14−177
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

18. CHECK THE INTERNAL DIAMETER OF THE CYLINDER

(a) Measure the inner diameter of the cylinder with a caliper in
the positions A, B, and C and in the axial and em- directions
I pray.
Standard diameter:
92.000 to 92.012 mm (3.6220 to 3.6225 in.)
Maximum diameter: 92.080 mm (3.6252 in.)
If the diameter is greater than the maximum, change the cylinder block.
dros.
Sense of
push
Front
Axial sense

A 10 mm

C 10 mm
A78801

19. INSPECT THE PISTON SUBASSEMBLY WITH

Belt
(a) Measure the diameter of the piston with a micrometer. When measuring
the diameter, set the micrometer to 13.0 mm (0.512
(in.) from the bottom of the piston and at a right angle r
I inspect the hole of the bolt.
Piston diameter:
13.0 mm 91.953 to 91.967 mm (3.6202 to 3.6207 in.)
A78316

20. VERIFICATION OF THE CALIBRATION FOR THE PISTON OIL

From the measurement of the inner diameter of the cylinder, subtract the measurement of the piston diameter.
Standard calibration for oil: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum calibration for the oil: 0.13 mm (0.0051 in.)
If the measured calibration exceeds the maximum value, change the 6 pistons. If necessary, change the block.
of cylinders.
21. INSPECT THE CONNECTING ROD ASSEMBLY
(a) Measure the alignment of the connecting rod with an aligner and a
calibration gauge.

Check that it is not misaligned.

Maximum misalignment:
0.05 mm (0.0020 in) per 100 mm (3.94 in)
If the misalignment exceeds the maximum value, change the assembly.
of the connecting rod.

Z00064
14−178
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(2) Check that it is not bent.

Maximum twisting:
0.15 mm (0.0059 in) by 100 mm (3.94 in)
If the twisting exceeds the maximum, change the assembly of
the axle.

Z00065

22. CHECK THE CALIBRATION FOR THE OIL OF

PISTON BOLT
(a) Measure the inner diameter of the connecting rod bushing with a caliper.
dor.
Inner diameter of the hub:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)

EM6525

Measure the piston pin with a micrometer.

Diameter of the piston bolt:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
The measurement of the inner diameter of the hub remains the diameter of the
metro of the piston bolt.
Standard calibration for oil:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum calibration for the oil: 0.05 mm (0.0020
EM0227 pulg.)
If the calibration is above the maximum, replace the bush.
necessary, change the piston and the pin.
23. EXTRACT THE HUB FROM THE CONNECTING ROD FOOT
SST Press the bushing out using a SST and a press.
SST 09222−30010

A78803

24. INSTALL THE WHEEL HUB OF THE CRANK ARM

Align the oil holes of the new bushing and the connecting rod.

Orifice
for the
oil

A78804
 14−179
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(b) Insert the bushing with a SST and a press.

SST 09222−30010
SST

A78803

File the bushing with a grindstone until achieving the calibration is-
standard between the sleeve and the piston bolt.
Standard calibration for oil:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)

EM6535

ADVICE:
Check the fit of the piston bolt at ambient temperature.
cylinder. Grease the piston bolt with motor oil and insert
Twist it with your thumb on the connecting rod.

P00326

25. CHECK THE CALIBRATION OF THE SLOTTED

SEGMENT
(a) Measure the calibration between the segment with a gauge
new piston and the wall of its groove.
Calibration of the segment slot:
No.1: 0.03 to 0.08 mm (0.0012 to 0.0031 in.)
No.2: 0.02 to 0.06 mm (0.008 to 0.0024 in.)
Oil: 0.03 to 0.11 mm (0.0012 to 0.0043 in.)
A78317

26. CHECK THE SEPARATION OF THE ENDS OF

THE PISTON SEGMENTS
(a) Using a piston, push the piston segment one po-
or beyond the bottom of its range, 110 mm (4.33
inches) from the top of the cylinder block.

110 mm

A78805
14−180
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(b) Measure the separation of the ends with a caliper gauge.

bration.
Standard separation of ends:
No.1: 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No.2: 0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil (side rail): 0.15 to 0.40 mm (0.0059 to 0.0157
pulg.)
Maximum separation of extremes:
A37355 No.1: 0.95 mm (0.0374 in.)
No.2: 1.05 mm (0.0413 in.)
Oil (side rail): 1.00 mm (0.0394 in.)
27. INSPECT THE BOLT OF THE CONNECTING RODS
(a) Measure the diameter of the segment subjected to tension of the
bolt with a caliper.
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 below the minimum, replace the bolt.

EM6347 A15065

28. INSPECT THE BOLTS OF THE COVERS OF THE

CRANKSHAFT BEARINGS
(a) Measure the diameter of the tensioned segment of the
bolt with a vernier.
Standard diameter:
7.5 to 7.6 mm (0.295 to 0.299 in)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than the minimum, change the bolt.
EM6347 A15065

29. INSPECT THE CRANKSHAFT

a) Measure the ovalization with a quadrant indicator and blo-
V-shaped questions as illustrated.
Maximum ovalization: 0.06 mm (0.0024 in.)

P12406

(b) Measure the diameter of each main stump with a micrometer

metro.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
(c) Compruebe la conicidad y la ovalización de cada uno de
the main stumps as shown in the illustration
cession.
Maximum conicity and ovality:
0.02 mm (0.0008 in.)
A37157
 14−181
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

Measure the diameter of each little doll with a micrometer.

Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
(e) Check the conicity and ovalization of each one of
the little dolls as shown in the illustration.
Maximum conicity and ovalization:
0.02 mm (0.0008 in.)

ZF6928

30. CALIBRATION VERIFICATION FOR THE

No.1 and 4 No.2 and 3 CRANKSHAFT OIL
ADVICE:
Superior
The main bearings come with widths of 22.4 mm.
22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm ones.
Inferior
(0.882 in.) in positions 1 and 4 of the block stub
cylinders with the main bearing cap. Install the 19.0 ones.
19.0 mm mm (0.748 in.) in positions 2 and 3.
22.4 mm
A78806 (a) Clean all the stubs and main bearings.

Align the bearing claw with the corresponding slot

from the cylinder block and push the 4 upper bearings
res.
NOTICE:
Do not grease the bearing or its contact surface.

P12599

(c) Align the bearing claw with the corresponding groove

from the main bearing cover and push the 4 bearings
inferior.
NOTICE:
Do not grease the bearing or its contact surface.
ADVICE:
Brand Each main bearing cap has a number that indicates the
1, 2, 3 or 4
installation position.
A78807 (d) Position the crankshaft on the cylinder block.

Plastigage (e) Place a strip of Plastigage on each journal.

A78808
14−182
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(f) Check the front marks and numbers and install the ta-
bearing pads in the cylinder block.
Apply a thin layer of motor oil on the thread
of the bolts for the bearing covers.
(h) Temporarily install the 8 bolts of the caps of the
bearings in the inner positions.

A10530

(i) Manually install the main bearing cap using the per-
no internal as a guide. Stop when the lid is en-
approximately 6 mm (0.23 in) of steel -
please to the block.

Less than 6 mm
A78809

(j) Gently tap the bearing cap with a hammer.

plastic head until properly adjusted.
Apply a thin layer of motor oil to the thread.
of the bolts of the main bearing caps.

A10529

(l) Install and evenly tighten the 16 bolts in stages.

from the bearing cover in the sequence illustrated.
Torque: 22 N⋅m (224 kgf⋅cm, 16 lbf⋅pie)
13 5
9 6
11 2
1 14
15 3 10
7 4 12
8 16
A78810

(m) Mark the front part of the bolts with paint.

90 Painted brand
bearingsthe
Re-tighten covers.
lid bolts to 90 degrees in the same place.
Front 90_
The sequence
painted that
markthe step
must(l). now form a 90-degree angle.

regarding the front part.

NOTICE:
Do not turn the crankshaft.

A78811
 -169
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(p) Install and uniformly tighten the 8 bolts in stages.

4
1 from the bearing cover in the sequence illustrated.
2 Torque: 27 N⋅m (275 kgf⋅cm, 20 lbf⋅pie
3 7 ADVICE:
Install a short bolt at the marked place (arrow).
6 Remove the caps from the main bearings.
5
8
A78812

(r) Place the Plastigage strip on the widest part.

Standard calibration for the oil:
Stumps 1 and 2
0.014 to 0.031 mm (0.0006 to 0.0012 in.)
Stumps 3 and 4
0.028 to 0.041 mm (0.0011 to 0.0016 in.)
Maximum calibration:
Stubs 1 and 2: 0.05 mm (0.0020 in.)
P12993 Stumps 3 and 4: 0.06 mm (0.0024 in.)
If the calibration is above the maximum, change the bearings. If
It is necessary, change the crankshaft.
NOTICE:
Remove the Plastigage strip.

No.2 If you change a bearing, replace it with another of the same number.
No.1 No.3
No.4 If you do not know the bearing number, add the numbers.
printed on the engine block and the crankshaft and afterwards
Consult the table below. The bearings of the journals
1 and 2 come in various sizes marked with the nu-
Number mark meros "3", "4", "5", "6" and "7". The bearings of the spindles
3 and 4 come in 5 standard sizes marked with the nu-
meros "1", "2", "3", "4" and "5".
Bearings of journals 1 and 2
No.2 No.3 Block of
No.4
No.1 cylinders (A)
+ 0 to 5 6to11 12 to 17 18 to 23 24 to 28
Crankshaft
(B) =
Use
3 4 5 6 7
the bearing

ADVICE:
EXAMPLE
Brand
of number Number mark Cylinder block '06' (A) + Crankshaft '08' (B)
A78813 Total number: 14 (use bearing '5')
14−184
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

Bearings of the pins 3 and 4

Block of
cylinders (A)
+ 0 to 5 6to11 12 to 17 18 to 23 24 to 28
Crankshaft
(B) =
Use
1 2 3 4 5
the bearing

ADVICE:
EXAMPLE
Cylinder block '06' (A) + Crankshaft '08' (B)
Total number: 14 (use bearing '3')

Element Brand mm (inches)

Inner diameter of the main stub of the block 00 66,000 (2.5984)
of cylinders (A) 01 66.001 (2.5985)
02 66.002 (2.5985)
03 66.003 (2.5985)
04 66.004 (2.5986)
05 66.005 (2.5986)
06 66.006 (2.5987)
07 66.007 (2.5987)
08 66.008 (2.5987)
09 66.009 (2.5988)
10 66.010 (2.5988)
11 66.011 (2.5989)
12 66.012 (2.5989)
13 66.013 (2.5989)
14 66.014 (2.5990)
15 66.015 (2.5990)
16 66.016 (2.5990)
Diameter of the main crankshaft pin (B) 00 61.000 (2.4016)
01 60.999 (2.4015)
02 60.998 (2.4015)
03 60.997 (2.4015)
04 60.996 (2.4014)
05 60.995 (2.4014)
06 60.994 (2.4013)
07 60.993 (2.4012)
08 60.992 (2.4012)
09 60.991 (2.4012)
10 60.990 (2.4012)
11 60.989 (2.4011)
12 60.988 (2.4011)
Standard thickness of the central wall of the bearing 1 2.486 to 2.489 (0.0979 to 0.0980)
2 2.489 to 2.492 (0.0980 to 0.0981)
3 2.492 to 2.495 (0.0981 to 0.0982)
4 2.495 to 2.498 (0.0982 to 0.0983)
5 2.498 to 2.501 (0.0983 to 0.0985)
6 2.501 to 2.504 (0.0985 to 0.0986)
7 2.504 to 2.507 (0.0986 to 0.0987)
 14−185
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

31. INSTALL THE PRISONER SPAR

Front part Front part

99 mm
29 mm

M6 M8
Torque: 6.0 N⋅m (60 kgf)⋅cm, 53 lbf⋅bug) Torque: 15 N⋅m (145 kgf⋅cm,11lbf⋅pie

Front part Left side

80 mm
28.5mm

M10 M8

Twisting torque: 21 N⋅m (220 kgf⋅cm, 15lbf⋅pie Torque: 7.0 N⋅m (70 kgf)⋅cm,62lbf⋅pulg.)

Top side Top part

52.5 mm
27.5 mm

M6

Torque: 4.0 N⋅m (40 kgf⋅cm, 35 lbf⋅pulg.) Torque: 12 N⋅m (122 kgf⋅cm, 9lbf⋅pie
A78318
14−186
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

32. INSTALL THE STRAIGHT PIN

Front part Right side (front)

4 mm 4 mm

12 mm 12 mm

Height of the protruding part: 6 mm Height of the protruding part: 6 mm

Top part Bottom part

4 mm 4 mm

12 mm 12 mm

Height of the protruding part: 6 mm Height of the protruding part: 6 mm

Back part Rear part

4 mm 10 mm

12 mm 22 mm

Projection height: 6 mm Height of the protruding part: 11 mm

A78319
 -173
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

33. INSTALL THE RING PIN

Top part

11 mm
16 mm

20 mm 8 mm

Height of the protruding part: 10 mm Height of the protruding part: 4 mm

A78816

34. INSTALL THE RETAINING RING OF THE ORIFICE

FROM THE PISTON BOLT
(a) Install a new retaining ring at one end of the ori-
tightening the bolt of the piston with a small screwdriver.
ADVICE:
Ensure that the separation of the ends of the retaining ring...
the section is not aligned with the cut part of the piston hole.

P12418 A32958

80_C (176_F)
35. INSTALL THE PISTON SUBASSEMBLY WITH THE
Buckle heat the piston to about 80_C (176_F)
Gradually

approximately.

A78817

Grease the piston bolt with motor oil.

Front mark (c) Align the front marks of the piston and the connecting rod and introduce
Lantern brand tighten the bolt with your thumb until it touches the ring
(printed brand) retention.

A78376
14−188
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

36. INSTALL THE RETENTION RING OF THE ORIFICE

FROM THE PISTON BOLT
(a) Install a new retaining ring at the other end of the
piston bolt hole with a small screwdriver.
ADVICE:
Ensure that the end of the retaining ring space does not
it should be aligned with the cut part of the piston hole.

P12418 A32958

37. INSTALL THE PISTON SEGMENT ASSEMBLY

(a) Install the lubrication ring spacer and the 2 rails
No.1 lateral to hand.
(b) Install the 2 compression rings with an expander
2A piston rings.
No.2 ADVICE:
The compression ring No.2 is installed with the printed code
“2A” orientado hacia arriba según se ilustra.
A78320

(c) Position the piston segments so that their ends

Bottom lane
they should be arranged as shown in the illustration.
Compression Brand
of No.2 forward NOTICE:
Do not align the ends of the piston rod.
Expander

Compression
of No.1
Top rail
A78321

38. INSTALL THE CONNECTING ROD BEARING

Align the bearing claw with the corresponding slot
of the connecting rod or the hat.
NOTICE:
Clean the back of the bearing and the surface of the con-
touch with the connecting rod bearing. The surface must be smoothed.
dust and oil.

P12402

39. INSTALL THE CRANKSHAFT BEARING

No.1 and 4 No. 2 and 3 ADVICE:
The main bearings come with widths of 22.4 mm.
Superior
(0.882 in) and 19.0 mm (0.748 in). Install the 22.4 mm ones.
Inferior
(0.882 in.) in positions 1 and 4 of the block stub.
cylinders with the main bearing cap. Install the 19.0 ones
mm (0.748 in.) in positions 2 and 3.
19.0 mm Clean all the stubs and main bearings.
22.4 mm
A78806
 -175
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

Align the bearing claw with the corresponding slot

of the cylinder block and push the 4 upper bearings
res.
NOTICE:
Do not grease the bearing or its contact surface.

P12599

Align the bearing claw with the corresponding slot

from the main bearing cover and push the 4 bearings
inferiors.
NOTICE:
Do not grease the bearing or its contact surface.
ADVICE:
Brand Each main bearing cap has a number that indicates the
1, 2, 3 or 4
installation position.
A78807

40. INSTALL THE WASHER ASSEMBLY OF

CRANKSHAFT PUSH
(a) Install the two thrust washers under the position of the
stump No.2 of the cylinder block with the grooves of
oil outward.

P12600

(b) Place the 2 thrust washers in the bearing cover

No.2 with the slots facing outward.
41. INSTALL THE CRANKSHAFT
Lubricate the upper bearing with engine oil and install it.
the crankshaft in the engine block.

A05264

Examine the front marks and numbers and install the ta-
not of the bearings in the cylinder block.
Apply a thin layer of motor oil on the thread.
of the bolts of the caps for bearings.
(d) Temporarily install the 8 bolts of the caps
bearings in the inner positions.

A10530
-176
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

(e) Manually install the main bearing cap using the per-
not internal as a guide. Stop when the lid is on
approximately 6 mm from coupling to the block.

Less than 6 mm
A78809

(f) Gently tap the bearing cap with a hammer.

plastic head until adjusting it correctly.
Apply a thin layer of motor oil on the thread.
of the bolts of the main bearing caps.

A10529

(h) Install and evenly tighten the 16 bolts in stages.

from the bearing cover in the sequence that is illustrated.
Torque: 22 N⋅m (224 kgf⋅cm, 16 lbf⋅pie
13 5
9 6
11 2
1 14
15 3 10
7 4 12
8 16
A78810

(i) Mark with paint the front part of the bolts of the
90 Painted brand
bearing covers.
Re-tighten the cover bolts to 90 on the same.
Front 90_ (j)
The sequence
painted that the step
mark must(h). now form a 90-degree angle.

regarding the front part.

(l) The crankshaft must turn smoothly.

A78811

(m) Install and tighten the 8 bolts evenly in stages

4
1 from the bearing cover in the sequence illustrated.
2 Torque: 27 N⋅m (275 kgf⋅cm, 20 lbf⋅pie
3 7 ADVICE:
Install the short bolt at the marked location (arrow).
6
5
8
A78812
 14−191
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

42. INSTALL THE PISTON SUBASSEMBLY WITH THE

Front mark (cavity)
WHITE
a) Grease the walls of the cylinders, the pistons and the
surfaces of the connecting rod bearings with engine oil.
Check the position of the endpoints of the segments
of the piston.
Front
(c) With a piston segment compressor, push the piston.
tone of the appropriate number and the assemblies of the connecting rods

A78322 into each cylinder with the front mark of the

piston forward.
NOTICE:
Front Each connecting rod cap must go on the connecting rod of its same number.
Check that the protruding part of the hat of
the white one is oriented in the right direction.
Apply a thin layer of motor oil to the thread.
of the bolts of the connecting rod cover.
Outgoing

A78794

(f) Tighten the bolts step by step according to the specifications.

torsion songs.
Torque: 25 N⋅m (250 kgf⋅cm, 18 lbf⋅pie

P12697

(g) Mark the front part of each bolt with paint

Painted brand
90_ (h) the little hats
Tighten theof the bushing.
bolts to 90 as illustrated.
90_

(i) The crankshaft must turn smoothly.

Front

A78795

Front part 43. INSTALL STRAIGHT SCREW PLUG WITH HEAD

NO.1 IN THE CYLINDER BLOCK
(a) With the help of a straight 10 mm hexagonal key,
that a new gasket and a new threaded plug.
Torque: 30 N⋅m (306 kgf⋅cm, 22 lbf⋅pie

A78822
-178
ENGINE MECHANICS - ASSEMBLY OF THE CYLINDER BLOCK

44. INSTALL THE STRAIGHT THREADED PLUG WITH HEAD

Left side
NO.2 IN THE CYLINDER BLOCK
(a) With the help of a straight hexagonal wrench of 10 mm, colo-
that a new gasket and a new threaded plug.
Torque: 30 N⋅m (306 kgf)⋅cm, 22 lbf⋅pie)

A78823

Back part 45. INSTALL THE STRAIGHT SCREW PLUG WITH HEAD
NO.3 IN THE CYLINDER BLOCK
(a) Using a straight hexagonal key of 10 mm,
that a new gasket and a new threaded plug.
Torque: 50 N⋅m (510 kgf⋅cm, 37 lbf⋅pie
46. INSTALL THE WATER SEAL PLATE
Remove the residue of sealant from the contact surface.

A78824

(b) Apply a uniform layer of sealant (3 to 5 mm (0.12

A a 0.20 inch in diameter) as illustrated.
Sealant: Part No. 08826-00100 or equivalent product
A lens
NOTICE:
B S
Clean all traces of oil from the contact surface.
to.
Width of the seal S
3 to 5 mm Install the seal plate within a period of 3 mi-
B A62377 Minutes after applying the sealant.
S
Wait 2 hours before exposing the sealer to oil
the engine.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N⋅m (184 kgf)⋅cm, 13 lbf⋅pie
47. INSTALL THE SUBASSEMBLY OF KEY D
Cylinder Block Cover
Apply adhesive to 2 or 3 threads at the end of the key
of drainage.
Adhesive: Part No. 08833−00070, THREE BOND
1324 or the equivalent
 14−193
ENGINE MECHANICS – ASSEMBLY OF THE CYLINDER BLOCK

After applying the specified torque, turn the

drainage key to the right as illustrated.
Torque: 39 N⋅m (398 kgf⋅cm, 29 lbf⋅pie
NOTICE:
S
Install the drain key within a period of 3
minutes after applying the adhesive.
S
Wait an hour before exposing it to the antifreeze.
you.
Do not turn the drain key more than 1 turn (360_) de-
S

after tightening them to the specified torque.

S
10 Do not loosen the drain valve until it is properly adjusted.
ta-da.
45_
A78323