NO FORM : QAUTR - 04 - 0

UNIT MODEL
UNIT S/N

ASSEMBLY CHECK SHEET ENGINE MODEL

ENGINE S/N
QA4 PROD NO
SHORT BLOCK 107 PAGE 1OF4
SERIES SECTION
CUSTOMER NAME

START DATE
PROCESS ASSEMBLY BY
FINISH DATE
CHECK
NO PARTS NAME CONDITION TO BE CHECKED SPEC CHECK NOTES, DIAGRAM, COMMENTS.
POINT
1 CYLINDER - Check that all oil holes are free from
foreign matter such as chips or dirt.
- Make sure that all U - plugs and blind
plugs have been installed.
- Tightening plug :

* Hex plug 5 mm : Actual: kg.m.

* Hex plug 14 mm : Actual: kg.m.

322.90 -
- Measure deck height : mm. 323.10 mm
Oversize head gasket required: YES NO

2 Tappet 1) Apply engine oil (EO15W-40) to tappets

(1).
2) Install 12 tappets (1).
a When reusing the camshafts and tappets,
be sure to install them in the
original position.
a Don't invert the cylinder block by 90°
or more. Otherwise, the tappet may
fall off from the mounting hole during
assembly.

3 Piston cooling Set 6 piston cooling nozzles (2) and then

nozzle tighten them using mounting bolt (1). 3Mounting bolt:
15 ± 2 Nm {1.5 ± 0.2 kgm}
4. Crankshaft
1) Install 6 upper bearings (6) and an upper
thrust bearing (5).
a Set the projection of each bearing to
the notch of the cylinder block.
a When installing the bearings, check
that their back sides are free from foreign
matter.
a Apply engine oil (EO15W-40) to inner
surface of metal. Don't apply the oil to
the backside.
a When reusing the bearings, check the
marks made on them when removed
and install them to their original positions

4 Crankshaft 1) Install 6 upper bearings (6) and an upper

thrust bearing (5).
a Set the projection of each bearing to
the notch of the cylinder block.
a When installing the bearings, check
that their back sides are free from foreign
matter.
a Apply engine oil (EO15W-40) to inner
surface of metal. Don't apply the oil to
the backside.
a When reusing the bearings, check the
marks made on them when removed
and install them to their original positions
2) Using a nylon sling, lift up and install
crankshaft (4).
a When installing, take care so that the
upper thrust bearing may not be damaged.
4 Crankshaft: 60 kg

SHORTBLOCK ASSEMBLY A
 NO FORM : QAUTR - 04 - 0
UNIT MODEL
UNIT S/N
ASSEMBLY CHECK SHEET ENGINE MODEL
ENGINE S/N

SHORT BLOCK 107

QA4 PROD NO
PAGE 2OF4
SERIES SECTION
CUSTOMER NAME

START DATE
PROCESS ASSEMBLY BY
FINISH DATE
CHECK
NO PARTS NAME CONDITION TO BE CHECKED SPEC CHECK NOTES, DIAGRAM, COMMENTS.
POINT
3) Fit lower bearing (3) to the main cap,
matching the projection of the former to
the notch of the latter.
a Make sure ring dowel (7) is installed
on the main cap.
4) Apply engine oil (EO15W-40) to the journal
surfaces of the crankshaft.
5) Before installation, check the No. stamped
on main cap (1).
- Installation shall start from the front
side of the cylinder block in a numerical
order.
- In the installation, make sure the
stamped No. (section A) is faced to
the oil cooler.
- Push in each main cap by hitting it
lightly with a plastic hammer or rubber
hammer.
6) Before tightening the main cap mounting
bolt (2), check the following.
- Measure stem length (a) of every bolt
to make sure that they are within the
using limit.
- Using limit length of bolt stem:

Less than 120 mm

- If a bolt is longer than the using
limit, do not reuse it but replace it

7) Tightening procedure of main cap mounting

bolts (2).
- Apply engine oil (EO15W-40) to the bolt

- Tightening shall be done according to

the sequence [1] o [14] shown in the figure

- Main cap mounting bolt

- Main cap mounting bolt
When current bolts are used again:
1] 60 ± 5 Nm {6.1 ± 0.5 kgm}
2] 80 ± 5 Nm {8.2 ± 0.5 kgm}
3] 90° ± 5° (When angle tightening
tool J is used)
When new bolts are used:
1] 120 ± 5 Nm {12.2 ± 0.5 kgm}
2] Loosen by 360°
3] 60 ± 5 Nm {6.1 ± 0.5 kgm}
4] 85 ± 5 Nm {8.7 ± 0.5 kgm}
5] 120° ± 5° (When angle tightening tool
J is used)
ACTUAL
BOLT NEW / OLD
1
2
3
4
5

8) After tightening the bolts, make sure that

the crankshaft turns smoothly.
9) Measure the end play of the crankshaft
with a dial gauge.
End play X :0.065 – 0.415 mm
ACTUAL : mm

SHORTBLOCK ASSEMBLY B
 NO FORM : QAUTR - 04 - 0

UNIT MODEL
UNIT S/N
ENGINE MODEL
ENGINE S/N
QA4 PROD NO
SHORT BLOCK 107 PAGE 3OF4
SERIES SECTION
CUSTOMER NAME

START DATE
ASSEMBLY BY
FINISH DATE
CHECK
PARTS NAME CONDITION TO BE CHECKED SPEC CHECK NOTES, DIAGRAM, COMMENTS.
POINT
5 Piston and 1) Using tool D, fit piston rings (7) to the piston.
connecting rod
assembly 2) Installation of oil ring
- Set the oil ring so that its abutment joint
- comes in a position at 180° to the end of
expander (8).

3) Fit second ring (10) with the stamp of

“TOP” near the abutment joint up.

4) Fit top ring (11) with the “dot” mark near

the abutment joint up.

5) When fitting each ring, set the abutment

joint off the thrust, anti-thrust, and piston
axis directions.

6) Apply engine oil (EO15W-40) to piston

ring and piston skirt.

7) Set the piston and connecting rod.

- When “FRONT” mark of piston (6)
head is set at the top, connecting rod (4)
must be facing to the direction
shown in the figure.
1] Apply engine oil (EO15W-40) to the
piston pin hole and piston pin.
2] Insert piston pin (5) and then assemble
piston (6) to connecting rod (4).
3] Install snap ring (3) to both sides.

8) Install the bearing to the connecting rod

and connecting rod cap.
- Check that the back side of the bearing
is free from foreign matter.
- Fit the bearing to the connecting rod
and cap, matching the projection of
the former to the notch of the connecting
rod and cap.

9) Set the crankshaft to the bottom dead

center of the cylinder to install the piston
and apply engine oil (EO15W-40) to the
inside of the cylinder.

10) Insert the piston and connecting rod

assembly setting “FRONT” mark of piston
(6) to the front side of the cylinder.
- Check the directions of the abutment
joints of the piston rings again.
- When inserting the connecting rod,
take care not to damage the wall of
piston pin hole and piston pin.
- When installing the assembly, take
care so that it may hit the cooling nozzle.
- Using tool E, reduce the piston rings
and push in the piston head with a
wood bar, etc.

SHORTBLOCK ASSEMBLY D
 NO FORM : QAUTR - 04 - 0
UNIT MODEL
UNIT S/N
ASSEMBLY CHECK SHEET ENGINE MODEL
ENGINE S/N
QA4 PROD NO
SHORT BLOCK 107 PAGE 4OF4
SERIES SECTION
CUSTOMER NAME

START DATE
PROCESS ASSEMBLY BY
FINISH DATE
CHECK
NO PARTS NAME CONDITION TO BE CHECKED SPEC CHECK NOTES, DIAGRAM, COMMENTS.
POINT
11) Install connecting rod cap (2) by tightening
bolt (1) in the following procedure.
- Apply engine oil (EO15W-40) to the
threaded portions of the bolts and
inside of the connecting rod bearings.
Mounting bolts (Tighten both bolts alternatly)

1] 30 ± 3 Nm {3.06 ± 0.31 kgm}

2] 60 ± 5 Nm {6.12 ± 0.51 kgm}
3] 60° ± 5° (When angle tightening
tool J is used)
ACTUAL
1
2
3

12) After installing the piston and connecting

rod assembly, rotate the crankshaft to
make sure that it turns smoothly without
getting hung up.

13) Measure the side clearance between the

connecting rod and crankshaft with tool K.
Side clearance : 0.10 – 0.33 mm
ACTUAL : MM

REMARK :

MECHANIC APPROVED BY LEADER APPROVED BY SUPERVISOR

Name : Name : Name :

Date : Date : Date :

Signature Signature Signature

SHORTBLOCK ASSEMBLY E
 NO FORM : QAUTR - 05 - 0

UNIT MODEL
UNIT S/N
MEASUREMENT CHECK SHEET ENGINE MODEL
ENGINE S/N
QA5 PROD NO
CRANKSHAFT 107 PAGE 1OF1
SERIES SECTION
CUSTOMER NAME

START DATE
PROCESS MEASURE BY
FINISH DATE

NO ITEM CRITERIA (mm) RESULT / COMMENT

1 End play (A) 0.065 – 0.415
Outside diameter of main journal 82.962 – 83.013
Roundness of main journal Repair limit: 0.050
2
Taper of main journal Repair limit: 0.013
Clearance of main journal 0.04 – 0.12
Outside diameter of crank pin journa 68.962 – 69.013
3 Roundness of crank pin journal Repair limit: 0.050
Clearance of crank pin journal 0.04 – 0.12
Outside diameter of crankshaft gear
4
journal 70.59 – 70.61
Inside diameter of crankshaft gear
5
journal 70.51 – 70.55

CRITICAL INSPECTION CHECK POINT ( mm ) RESULT / COMMENT

End play (A)
1 2 3 4 5 6 7
X
Outside diameter of main journal Y
Roundness of main journal
Taper of main journal

1 2 3 4 5 6 RESULT / COMMENT
Outside diameter of crank pin journa
Roundness of crank pin journal
Clearance of crank pin journal
Outside diameter of crankshaft gear journal
Inside diameter of crankshaft gear
Max 0.15 ( TIR )
BENDING CRANKSHAFT
REMARK

MECHANIC APPROVED BY LEADER APPROVED BY SUPERVISOR

Name : Name : Name :

Date : Date : Date :

Signature Signature Signature

SHORTBLOCK ASSEMBLY CRANKSHAFT 1

 NO FORM : QAUTR - 05 - 0

SHORTBLOCK ASSEMBLY CRANKSHAFT 1