Part One

Connecting Rod Bearing Replacement

Installation

1. Connecting Rod Bearing Clearance Inspection





1. Clean the connecting rod journal and the bearing half with a clean shop towel.

2. Place plastigage across the rod journal.

3. Reinstall the bearing half and the cap, then torque the bolts to 20 Nm (2.0 kgfm, 15 lbfft) +90 °.

NOTE:
* Apply new engine oil to the bolt threads and flanges.
* Do not rotate the crankshaft during inspection.

4. Remove the connecting rod cap and the bearing half, and measure the widest part of the plastigage.







5. If the plastigage measures too wide or too narrow, remove the cap, and the upper half of the bearing. Install a new, complete bearing with the appropriate color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance.

6. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below the current one), and check the clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

2. Connecting Rod Bearing Selection

1. Inspect each connecting rod for cracks and heat damage.






2. Each connecting rod has a tolerance range from 0 to 0.024 mm (0.00094 in), in 0.006 mm (0.00024 in) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3, or 4/I, II, III, or IIII) indicating the range. You may find any combination of numbers and bars in any engine. (Half the number or bar is stamped on the rod cap, the other half is on the connecting rod.) If you cannot read the code because of an accumulation of oil and varnish, do not scrub it with a wire brush or scraper. Clean it only with solvent or detergent.












3. The connecting rod journal codes are stamped on the crankshaft in either location.





4. Use the big end bore codes and the rod journal codes to select appropriate replacement bearings from the following table.

NOTE:
* Color code is on the edge of the bearing.
* When using bearing halves of different colors, it does not matter which color is used in the top or bottom.

3. Connecting Rod Cap and The Bearing Half





1. Apply new engine oil to the threads of the connecting rod bolts.

2. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the bearing cap.

3. Install the bearing caps and the bolts finger-tight.

4. Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and the bearing cap.

5. Install the bearing caps and the bolts finger-tight.





6. Torque the connecting rod bolts to 20 Nm (2.0 kgfm, 14 lbfft).

7. Tighten the connecting rod bolts an additional 90 °.

NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen it back to the specified angle.

4. Engine Baffle Plate





1. Install the baffle plate.

5. Engine Oil Strainer





1. Install the oil strainer (A) with new O-ring (B).

6. Oil Pan Assembly





1. Remove all of the old liquid gasket from the oil pan mating surfaces, the bolts, and the bolt holes.

2. Clean and dry the oil pan mating surfaces.

3. Apply liquid gasket, (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pan, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





4. Install the dowel pins (A).

5. Install the oil pan (B) with new O-rings (C).





6. Tighten the bolts in three steps. In the final step, torque all bolts, in sequence, to 18 Nm (1.8 kgfm, 13 lbfft). Wipe off the excess liquid gasket on the each side of crankshaft pulley and flywheel/drive plate.

NOTE:
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine within 3 hours after installing the oil pan.

7. Cylinder Head Assembly





1. Clean the cylinder head and the engine block surface.

2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.

3. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.

4. Install the cylinder head on the engine block.





5. Measure the diameter of each cylinder head bolt at point A and point B.

6. If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.





7. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.

8. Torque the cylinder head bolts in sequence to 40 Nm (4.1 kgfm, 30 lbfft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.





9. After torquing, tighten all cylinder head bolts in two steps (90 ° per step using the sequence shown in step 8). If you are using a new cylinder head bolt, tighten the bolt an extra 60 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure. Do not loosen it back to the specified angle.

8. Set The No.1 Piston at Top Dead Center (Without Cam Chain Case/Oil Pump)





1. Set the camshaft to TDC. The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

9. Cam Chain





1. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the mark (B) on the crankshaft sprocket.





2. Install the cam chain on the camshaft sprocket with the colored link plate (A) aligned with the mark (B) on the camshaft sprocket.





3. Install the cam chain guide (A) and the cam chain tensioner arm (B).

10. Cam Chain Auto-Tensioner





1. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.0 mm (1/32 in) diameter pin back into the holes (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.





2. Install the cam chain auto-tensioner.





3. Remove the pin from the cam chain auto-tensioner.

11. Engine Oil Pump Assembly





1. Check the oil pump oil seal for damage. If the oil seal is damaged, replace the oil seal.

2. Remove all of the old liquid gasket from the oil pump mating surfaces, the bolts, and the bolt holes.

3. Clean and dry the oil pump mating surfaces.

4. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A), (B), and (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





5. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.









6. Set the edge of the oil pump (A) on the edge of the oil pan (B) with new O-rings (C).

7. Install the oil pump on the engine block (D).

8. Loosely install the dowel bolts (E), then tighten the 8mmbolts (F), the 6 mm bolts (G) and the dowel bolts.

9. Wipe off the excess liquid gasket on the oil pan and oil pump mating surface.

NOTE:
* When installing the oil pump, do not slide the bottom surface onto the oil pan mounting surface.
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine within 3 hours after installing the oil pump.

12. Crankshaft Oil Seal, Transmission side





1. Apply a light coat of new engine oil to the crankshaft and the lip of the crankshaft oil seal.

2. Use the driver handle and the oil seal driver attachment, 96 mm to drive a new crankshaft oil seal (A) squarely into the engine block to the specified installed height.





3. Measure the distance between the engine block (A) and the crankshaft oil seal (B).








13. Crankshaft Pulley





1. Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D).

2. Lubricate with new engine oil as shown.





3. Install the crankshaft pulley (A) onto the crankshaft (B) by aligning the flat sides (C) of the pulley with the flat sides (D) of the inner oil pump gear.









When a new crankshaft or a new pulley bolt is installed

4. Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), torque the bolt to 180 Nm (18.4 kgfm, 133 lbfft) with a torque wrench and a socket (C), then remove the bolt.

5. Torque the bolt to 50 Nm (5.1 kgfm, 37 lbfft) with a torque wrench and a socket.

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

6. Tighten the bolt an additional 82 °.









When the crankshaft or the pulley bolt is reused

7. Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), then torque the bolt to 70 Nm (7.1 kgfm, 52 lbfft) with a torque wrench and a socket (C).

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

8. Tighten the bolt an additional 90 °.

14. Valve Clearance Adjustment





1. Set the No. 1 piston at top dead center (TDC). The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

2. Select the correct feeler gauge for the valve clearance you are going to check.
















3. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and slide it back and forth; you should feel a slight amount of drag.





4. If you feel too much or too little drag, loosen the locknut, and turn the adjusting screw (A) until the drag on the feeler gauge is correct.

5. Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.












6. Rotate the crankshaft clockwise. Align the No. 3 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

7. Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.





8. Rotate the crankshaft clockwise. Align the No. 4 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

9. Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.





10. Rotate the crankshaft clockwise. Align the No. 2 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

11. Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.

15. Cylinder Head Cover and/or Packing





1. Thoroughly clean the head cover gasket and the groove.

NOTE: Check and, if necessary, replace the head cover gasket.

2. Install the head cover gasket (A) in the groove of the cylinder head cover (B).

3. Make sure the head cover gasket is seated securely.

4. Clean the head cover contacting surfaces with a shop towel.





5. Remove the old liquid gasket from the top edge matting surfaces of the oil pump (A) and cylinder head (B).

6. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the chain case contact areas. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 5 mm (0.20 in) diameter bead of liquid gasket to the mating surfaces (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





7. Install the cylinder head cover.

8. Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 10 Nm (1.0 kgfm, 7 lbfft).

NOTE:
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine for at least 3 hours after installing the head cover.





9. Connect the breather hose (A).

10. Install the dipstick (B).