Part 2

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Part 2 Of 2:

CYLINDER BLOCK ASSEMBLY
OVERHAUL





21. INSPECT W/PIN PISTON SUB-ASSEMBLY
a. Using a micrometer, measure the diameter of the piston. When you measure the diameter, attach the micrometer to a location where 13.0 mm (0.512 inch) above from the piston bottom and meets at the right angles to the piston pin hole.
Piston diameter: 91.953 to 91.967 mm (3.6202 to 3.6207 inch)
22. INSPECT PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 inch)
Maximum oil clearance: 0.130 mm (0.0051 inch)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
23. INSPECT CONNECTING ROD SUB-ASSEMBLY
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.





1. Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If misalignment is greater than the maximum, replace the connecting rod assembly.





2. Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than the maximum, replace the connecting rod assembly.
24. INSPECT PISTON PIN OIL CLEARANCE





a. Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Bush inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)





b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
c. 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 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and the piston pin together.





25. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bush.
SST 09222-30010
26. INSTALL CONNECTING ROD SMALL END BUSH





a. Align the oil holes of a new bush and the connecting rod.





b. Using SST and a press, press in the bush.
SST 09222-30010





c. Using a pin hole grinder, hone the bushing to obtain the standard clearance between the bush and piston pin.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)





d. Check that the piston pin fits at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.





27. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.





Ring groove clearance

If the clearance is not as specified, replace the piston.
28. INSPECT PISTON RING END GAP





a. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.





b. Using a feeler gauge, measure the end gap.





Standard end gap





Maximum end gap

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.





29. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.20 to 7.30 mm (0.2830 to 0.2870 inch)
Minimum diameter: 7.0 mm (0.2760 inch)
If the diameter is less than the minimum, replace the bolt.





30. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.50 to 7.60 mm (0.2950 to 0.2990 inch)
Minimum diameter: 7.20 mm (0.2830 inch)
If the diameter is less than the minimum, replace the bolt.
31. INSPECT CRANKSHAFT





a. Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than the maximum, replace the crankshaft.





b. Using a micrometer, measure the diameter of each main journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 inch)
If the diameter is not as specified, check the oil clearance (see step 7).
If necessary, replace the crankshaft.
c. 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 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.





d. Using a micrometer, measure the diameter of each crankpin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
If the diameter is not as specified, check the oil clearance (see step 7).
e. 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 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.





32. INSTALL STUD BOLT





33. INSTALL STRAIGHT PIN





34. INSTALL RING PIN





35. INSTALL PISTON PIN HOLE SNAP RING
a. Using a small 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 pin hole cutout portion of the piston.

36. INSTALL W/PIN PISTON SUB-ASSEMBLY





a. Gradually heat the piston to about 80°C (176°F).





b. Coat the piston pin with engine oil.
c. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb until the pin contacts the snap ring.





37. INSTALL PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

HINT: Be sure that the end of gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

38. INSTALL PISTON RING SET





a. Install the oil ring expander and the 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings.

HINT: The compression ring No. 2 is installed with code mark "2A" faced upward, as shown in the illustration.





c. Position the piston rings so that the ring ends are arranged, as shown in the illustration.

NOTICE: Do not align the ring ends.





39. INSTALL CONNECTING ROD BEARING
a. Align the key of the bearing with the keyway of the connecting rod or connecting cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.





40. INSTALL CRANKSHAFT BEARING

HINT: Main bearings come in width of 22.4 mm (0.882 inch) and 19.0 mm (0.748 inch). Install the 22.4mm (0.882 inch) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 inch) bearings in the No. 2 and No. 3 positions.





a. Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings.

NOTICE: Do not apply engine oil to the bearing and its contact surface.





b. Align the key of the bearing with the keyway of the main bearing cap, and push in the 4 lower bearings.

NOTICE: Do not apply engine oil to the bearing and its contact surface.

HINT: A number is marked on each main bearing cap to indicate the installation position.

41. INSTALL CRANKSHAFT THRUST WASHER SET





a. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.





b. Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.
42. INSTALL CRANKSHAFT
a. Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.





b. Examine the front marks and numbers. Install the bearing caps on the cylinder block.
c. Apply a light coat of engine oil on the threads of the bearing cap bolts.
d. Temporarily install the 8 main bearing cap bolts to the inside positions.





e. Install the main bearing cap by hand using the inner bolt as a guide. Stop the main bearing cap about 6 mm (0.23 inch) away from contacting with the block.





f. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
g. Apply a light coat of engine oil on the threads of the main bearing cap bolts.





h. Uniformly install and tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





i. Mark the front side of the bearing cap bolts with paint.
j. Retighten the bearing cap bolts by 90° in the same sequence as step (h).
k. Check that each painted mark is now at a 90° angle to the front.
l. Check that the crankshaft turns smoothly.





m. Uniformly install and tighten the 8 main bearing cap bolts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

HINT: Use the short bolt for the marked positions (arrow).

43. INSTALL PISTON SUB-ASSEMBLY W/CONNECTING ROD





a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
b. Check the position of the piston ring ends.
c. Using a piston ring compressor, push the piston that numbered correctly and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTICE: Match the numbered connecting rod cap with the connecting rod.





d. Check that the protrusion of the connecting rod cap is facing the correct direction.
e. Apply a light coat of engine oil on the threads of the connecting rod cap bolts.





f. Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





g. Mark the front side of each connecting cap bolt with paint.
h. Retighten the cap bolts by 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.





44. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





45. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
a. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





46. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)





47. INSTALL WATER SEAL PLATE
a. Remove any old seal packing from the contact surface.
b. Apply a continuous bead of seal packing (seal width: 03 to 5 mm (0.12 to 0.20 inch), as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the seal plate within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

c. Install the seal plate with the 2 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
48. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. After applying the specified torque, rotate the drain cock clockwise, as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)

NOTICE:
^ Install the drain cock within 3 minutes after applying adhesive.
^ Do not expose the seal to coolant for at least 1 hour after installing.
^ Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock with the specified torque.
^ Do not loosen the drain cock after setting it correctly.