Part 2

CYLINDER BLOCK ASSEMBLY
OVERHAUL





26. 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:
No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 inch)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 inch)
Oil (Side rail) 0.15 to 0.40 mm (0.0059 to 0.0157 inch)
Maximum end gap:
No. 1 0.95 mm (0.0374 inch)
No. 2 1.05 mm (0.0413 inch)
Oil (Side rail) 1.00 mm (0.0394 inch)





27. 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 minimum, replace the bolt.





28. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 inch)
Minimum diameter: 7.2 mm (0.283 inch)
If the diameter is less than minimum, replace the bolt.
29. 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: 60.988 to 61.000 mm (2.4011 to 2.4016 inch)
c. Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)





d. Using a micrometer, measure the diameter of each crankpin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
e. Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
30. INSPECT CRANKSHAFT OIL CLEARANCE

HINT: Main bearings come in widths of 22.4 mm (0.882 inch) and 19.0 mm (0.748 inch). 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. Align the bearing key 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.





c. Align the bearing key 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.

d. Place the crankshaft on the cylinder block.





e. Lay a strip of Plastigage across each journal.





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





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





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





i. Using several steps, install and tighten the 16 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





m. Mark the front side of the bearing cap bolts with paint.
n. Retighten the bearing cap bolts by 90° in the same sequence shown as step (I).
o. Check that each painted mark is now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.





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

HINT: Use the short bolt for the marked position (arrow)

q. Remove the main bearing caps.





r. Measure the Plastigage at its widest point.
Standard oil clearance.
No. 1 and No. 2 journals 0.014 to 0.034 mm (0.0006 to 0.0013 inch)
No. 3 and No. 4 journals 0.026 to 0.046 mm (0.0010 to 0.0018 inch)
Maximum clearance:
No. 1 and No. 2 journals 0.05 mm (0.0020 inch)
No. 3 and No. 4 journals 0.06 mm (0.0024 inch)

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

NOTICE: Completely remove the Plastigage.





s. If replacing a bearing, replace it with one having 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. The No. 1 and No. 2 journal bearing come in sizes, marked "3", "4", "5", "6" and "7". The No.3 and No. 4 journal bearings come in 5 standard bearing sizes, marked "1", "2", "3", "4" and "5".





No. 1 and No. 2 journal bearings

HINT:
EXAMPLE
Cylinder block imprinted number mark is 06
Crankshaft imprinted number mark is 08
6 + 8 = 14
Select the bearing marked "5"





No. 3 and No. 4 journal bearings





HINT:
EXAMPLE
Cylinder block imprinted number mark is 06
Crankshaft imprinted number mark is 08
6 + 8 = 14
Select the bearing marked "3"





31. INSTALL STUD BOLT





32. INSTALL STRAIGHT PIN





33. INSTALL RING PIN





34. 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 end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

35. 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.





36. 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 end of gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

37. 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.





38. 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.





39. INSTALL CRANKSHAFT BEARING

HINT: Main bearings come in widths of 22.4 mm (0.882 inch) and 19.0 mm (0.748 inch). 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 the bearing.





b. 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.





c. 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.

40. 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.
41. INSTALL CRANKSHAFT
a. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.





b. Examine the front marks and numbers and 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 is 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. Using several steps, install and tighten the 16 main bearing cap bolts uniformly 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. Using several steps, install and tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

HINT: Use the short bolt for the marked position (arrow)

42. 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 correctly numbered piston 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 (250 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.





43. 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.)





44. 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.)





45. 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.)
46. INSTALL WATER SEAL PLATE
a. Remove any old seal packing from the contact surface.





b. Apply a continuous bead of seal packing (Diameter 3 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 within 2 hours after installing.

c. Install the seal plate with the 2 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
47. 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 within 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.