Part 2

OVERHAUL (CONTINUED)

31. INSPECT CRANKSHAFT OIL CLEARANCE

HINT:
- Keep the lower bearings and crankshaft bearing caps together.
- Arrange the thrust washers in the correct order.
- Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.

a. Clean each main journal and bearing.
b. Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearing.
c. Place the crankshaft on the cylinder block.





d. Lay a strip of Plastigage across each journal.





e. Install the 5 crankshaft bearing caps in their proper locations.
f. Install the 5 crankshaft bearing caps with the 10 bolts (see step 49).

NOTICE: Do not turn the crankshaft.

g. Remove the 10 bolts and 5 crankshaft bearing caps (see step 6).





h. Measure the Plastigage at its widest point.




Standard oil clearance

Maximum oil clearance:
0.10 mm (0.0039 inch)

If the oil clearance is greater than the maximum, replace the crankshaft bearing.

HINT:
- If replacing the cylinder block, measure the bearing standard clearance.
- If replacing a bearing, first check the number on the cylinder block for the bearing's respective journal. Then replace the bearing with one that has the same number. Each bearing's standard thickness is indicated by a 1, 2 or 3 mark on its surface.

Reference:




Cylinder block main journal bore diameter




Standard bearing center wall thickness

i. Completely remove the Plastigage.





32. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
Standard diameter: 10.76 to 10.97 mm (0.4236 to 0.4319 inch)
Minimum diameter: 10.66 mm (0.4197 inch)
If the diameter is less than the minimum, replace the bolt.





33. INSPECT NO.1 BALANCE SHAFT
a. Inspect the diameter of the journal.
(1) Using a micrometer, measure the diameter of the balance shaft main journals.





Main journal diameter





b. Inspect the diameter of bearing.
(1) Using a cylinder gauge, measure the inside diameter of the balance shaft bearing.





Bearing inside diameter

c. Inspect oil clearance.
(1) Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement.




Standard oil clearance

Maximum oil clearance: 0.15 mm (0.0059 inch)
If the oil clearance is greater than the maximum, replace the cylinder block and balance shaft.





34. INSPECT NO.2 BALANCE SHAFT
a. Inspect the diameter of the journal.
(1) Using a micrometer, measure the diameter of the balance shaft main journals.




Main journal diameter





b. Inspect the diameter of bearing.
(1) Using a cylinder gauge, measure the inside diameter of the balance shaft bearing.




Bearing inside diameter

c. Inspect oil clearance.




Standard oil clearance

Maximum oil clearance: 0.15 mm (0.0059 inch)
If the oil clearance is greater than the maximum, replace the cylinder block and balance shaft.





35. INSTALL TIGHT PLUG

NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.

a. Apply adhesive around the tight plugs.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.





b. Using SST and a hammer, tap in new tight plugs as shown in the illustration.
c. Using SST, tap in the 8 tight plugs A and C.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
d. Using SST, tap in the tight plug B.
SST 09950-60010 (09951-00300), 09950-70010 (09951-07100)





e. Using SST, tap in the 3 tight plugs D.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)
36. INSTALL STUD BOLT
a. Using an E7 torx socket wrench, install the stud bolts B and D.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.) for stud bolts B and D
b. Using an E8 torx socket wrench, install the stud bolts A.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.) for stud bolts A
c. Apply adhesive to the hole for the stud bolt C on the cylinder block. Using an E7 torx socket wrench, install the stud bolts C.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.) for stud bolt C





NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.





37. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.





38. INSTALL RING PIN
a. Using a plastic-faced hammer, tap in new ring pins to the cylinder block.





39. INSTALL BALANCE SHAFT DRIVEN GEAR NO.2
a. Mount the head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.

b. Install the balance shaft thrust washer No.2 (* 1) and balance shaft driven gear No.2 (* 2).
c. Install and torque the bolt.
Torque: 36 Nm (365 kgf-cm, 26 ft. lbs.)





40. INSTALL NO.2 BALANCE SHAFT
a. Install the balance shaft to the cylinder block.

NOTICE: When installing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.





b. Install and torque the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





41. INSTALL BALANCE SHAFT DRIVEN GEAR NO.1
a. Mount the head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.

b. Install the balance shaft thrust spacer (* 1), balance shaft thrust washer No.1 (* 2), sliding key (* 3) and balance shaft driven gear No.1 (* 4).
c. Install and torque the bolt.
Torque: 36 Nm (365 kgf-cm, 26 ft. lbs.)





42. INSTALL NO.1 BALANCE SHAFT
a. Install the No.1 balance shaft to the cylinder block.

NOTICE: When installing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.





b. Install and torque the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





43. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply adhesive around the drain cock.





b. Install the cylinder block water drain cock as shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18 inch lbs.)
c. Install the water drain cock plug to the water drain cock sub-assembly.
Torque: 13 Nm (130 kgf-cm, 9 inch lbs.)





44. INSTALL SUB-ASSEMBLY OIL NOZZLE NO.1
a. Using an E7 torx socket wrench, install the oil nozzles.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)





45. 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 bush to obtain the standard specified clearance (see step 26.) between the bush and piston pin.





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





46. INSTALL W/PIN PISTON SUB-ASSEMBLY
a. Assemble the piston and connecting rod.
(1) Using a screwdriver, install a new snap ring at one end of the piston pin hole.





(2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).





(3) Coat the piston pin with engine oil.
(4) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

HINT: The piston and pin are a matched set.





(5) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.





(6) Using a screwdriver, install a new snap ring at the other end of the piston pin hole.





47. INSTALL PISTON RING SET
a. Install the oil ring expander by hand.
b. Using a piston ring expander, install the oil ring rail.





c. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

HINT:
- Install the compression ring No.1 with the code mark (1N) facing upward.
- Install the compression ring No.2 with the code mark (2N) facing upward.





d. Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE: Do not align the ring ends.

48. INSTALL CRANKSHAFT BEARING

NOTICE:
- Do not apply engine oil to the bearing's contact area and backside.
- The crankshaft bearing cap bolt is tightened in 2 progressive steps.

a. Clean the main journal, and the both surfaces of the bearing.





b. Install the upper bearing.
(1) Install the upper bearing to the cylinder block as shown in the illustration.

NOTICE: Do not apply engine oil to the bearing's contact area and backside.





c. Install the lower bearing.
(1) Install the lower bearing to the bearing cap.
(2) Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B): 0.3 mm (0.0118 inch) or less





NOTICE: Do not apply engine oil to the bearing's contact area and backside.

d. With the upper bearing and lower bearing installed, use a plastic-faced hammer to install the bearing caps to the cylinder block.

NOTICE: Make sure that the bearing caps are installed in the correct positions and direction.





e. Using vernier calipers, measure the amount of misalignment between the upper bearing and lower bearing, as shown in the illustration.

Standard: 0.9 mm (0.035 inch) or less
f. Remove the bearing cap.





g. Install the crankshaft thrust washer upper to the cylinder block.
(1) Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.

NOTICE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged.





h. Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.

NOTICE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged. The bearing lower has a claw as shown in the illustration.

i. Apply engine oil to the lower bearing.
49. INSTALL CRANKSHAFT
a. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.





b. Install the 5 crankshaft bearing caps in their proper locations.





c. Install the crankshaft bearing cap bolts.

HINT: The main bearing cap bolts are tightened in 2 progressive steps.

d. Step 1
(1) Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.





e. Step 2
(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts by 90° in the order above.
(3) Check that the painted mark is now at a 90° angle to the front.
f. Check that the crankshaft turns smoothly.
g. Check the crankshaft thrust clearance (see step 5).





50. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the groove of the connecting rod or connecting cap.





b. Install the bearings in the connecting rod and connecting rod cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod.

51. 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. Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE: Do not align the ring ends.





c. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
d. Match the numbered connecting rod cap with the connecting rod.

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





e. Check that the front mark of the connecting rod cap is facing forward.
f. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.





g. Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





h. Mark the front side of each connecting cap bolt with paint.
i. Retighten the cap bolts by 90° as shown.
j. Check that the painted mark is now at a 90 angle to the front.
k. Check that the crankshaft turns smoothly.
l. Check the connecting rod thrust clearance (see step 1).