Part 2

OVERHAUL (CONTINUED)





23. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)
If the diameter is less than the minimum, replace the bolt.





24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 10.0 to 10.2 mm (0.393 to 0.402 inch)
If the diameter is less than the minimum, replace the bolt.





25. 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)





b. Using a micrometer, measure the diameter of each main journal.
Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 inch)
c. Check each main journal for taper and out-of-roundness as shown.
Maximum taper and out-of-roundness: 0.02 mm (0.0008 inch)





d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 inch)
e. Check each crank pin for taper and out-of-roundness as shown.
Maximum taper and out-of-roundness: 0.02 mm (0.0008 inch)





26. INSPECT CRANKSHAFT OIL CLEARANCE

HINT: There are 2 types of main bearings with different widths (19.0 mm (0.748 inch) and 22.4 mm (0.882 inch)) for use in the inspection. Install the 22.4 mm (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. Clean each main journal and bearing.





b. Install the 4 upper bearings.
(1) Install the upper bearing near the center of the cylinder block.

NOTICE:
- The width of the No.1 and No.4 journal bearings is different from that of the No.2 and No.3 journal bearings. Therefore, confirm whether it is the correct journal bearing prior to installation.
- Do not apply engine oil to the bearing installation surfaces of the cylinder block and the back side of the bearings.
- Check that the oil groove on the cylinder block can be seen through the oil supply holes of the upper bearing.





c. Install the 4 lower bearings.
(1) Install the lower bearing near the center of the cylinder block.

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

HINT: A number marked on each main bearing cap indicates the installation position.

d. Place the crankshaft on the cylinder block.





e. Lay a strip of plastigage across each journal.





f. Examine the front marks and numbers, check the sequence order is as shown and install the bearing caps onto the cylinder block.
g. Apply a light coat of engine oil to the threads of bearing cap bolts.
h. Temporarily install the 8 main bearing cap bolts in the inside positions.





i. Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 inch).





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





l. Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)





m. Mark the front side of the bearing cap bolts with paint.
n. Retighten the bearing cap bolts 90° in the sequence as shown.
o. Check that the painted mark is now at a 90° angle from the front.

NOTICE: Do not turn the crankshaft.





p. Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
q. Remove the main bearing caps.





r. Measure the Plastigage at its widest point.
Standard oil clearance: 0.018 to 0.030 mm (0.0007 to 0.0012 inch)
Maximum clearance: 0.046 mm (0.0018 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTICE: Completely remove the plastigage.





s. Replace the bearing with 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, then refer to the table for the appropriate bearing number. There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5" accordingly





Journal bearings





HINT: EXAMPLE
Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3")





27. INSTALL STUD BOLT
a. Install the stud bolts as shown in the illustration.
Torque:
11 Nm (112 kgf-cm, 8.1 ft. lbs.) for stud bolt A
4.5 Nm (46 kgf-cm, 40 inch lbs.) for stud bolt B





28. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap into the new straight pin.
Standard protrusion:
Pin A 22.5 to 23.5 mm (0.886 to 0.925 inch)
Pin B 10.5 to 11.5 mm (0.413 to 0.453 inch)
Pin C 8.5 to 9.5 mm (0.335 to 0.374 inch)
Pin D 5.5 to 6.5 mm (0.217 to 0.256 inch)
29. INSTALL TIGHT PLUG
a. Apply adhesive around tight plugs.
Adhesive: part No.08833 - 00070, THREE BOND 1324 or equivalent.





b. Using SST, install the tight plugs as shown in the illustration.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07150)
Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 inch)





30. INSTALL OIL JET
a. Using a screw driver and hammer, tap in a oil jet.





31. INSTALL SUB-ASSEMBLY OIL NOZZLE NO.1
a. Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





32. INSTALL RING, HOLE SNAP
a. Using a small screwdriver, install a new snap ring onto one side of the piston pin hole.

HINT: Check that an end gap of the snap ring is not overlapped with the pin hole cutout portion of the piston.





33. 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 thumb.





34. INSTALL RING, HOLE SNAP
a. Using a small screwdriver, install a new snap ring onto the other side of the piston pin hole.

HINT: Make sure that the gap in the snap ring does not overlap with the pin hole cutout portion of the piston.





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

NOTICE: Install the compression ring No.2 with the painted mark facing upward.





c. Position the piston rings so that the ring ends are as shown.





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

NOTICE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oils and fats.





37. INSTALL CRANKSHAFT BEARING

HINT: There are 2 types of main bearings with different widths (19.0 mm (0.748 inch) and 22.4 mm (0.882 inch)) for use in the inspection. Install the 22.4 mm (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. Clean each main journal and bearing.





b. Install the 4 upper bearings.
(1) Install the upper bearings near the center of the cylinder block.

NOTICE:
- The width of the No.1 and No.4 journal bearings is different from that of the No.2 and No.3 journal bearings. Therefore, confirm whether it is the correct journal bearing prior to installation.
- Do not apply engine oil to the bearing installation surfaces of the cylinder block and the back side of the bearings.
- Check that the oil groove on the cylinder block can be seen through the oil supply holes of the upper bearing.





c. Install the 4 lower bearings.
(1) Install the lower bearings near the center of the cylinder block.

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

HINT: A number marked on each main bearing cap indicates the installation position.

38. INSTALL CRANKSHAFT
a. Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.





b. Install the 2 upper thrust washers onto the No.2 journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil grooves facing outward.





c. Install the 2 lower thrust washers onto the No.2 bearing cap with the grooves facing outward.





d. Examine the front marks and numbers, check the sequence number is as shown in the illustration and install the bearing caps on the cylinder block.
e. Apply a light coat of engine oil to the threads of bearing cap bolts.
f. Temporarily install the 8 main bearing cap bolts in the inside positions.





g. Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 inch).





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





j. Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)





k. Mark the front side of the bearing cap bolts with paint.
l. Retighten the bearing cap bolts 90° in the sequence as shown.
m. Check that the painted mark is now at a 90° angle from the front.
n. Check that the crankshaft turns smoothly.





o. Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





39. INSTALL PISTON SUB-ASSEMBLY W/CONNECTING ROD
a. Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
b. Check the position of the piston ring ends.
c. Using a piston ring compressor, push the correct number piston and connecting rod into each cylinder with the front mark of the piston facing forward.

NOTICE:
- Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oils and fats.
- Match the numbered connecting rod cap with the connecting rod.





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





f. Using SST, tighten the bolts alternately to the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





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