Part 2

CYLINDER BLOCK ASSY 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 0.25 - 0.35 mm (0.0098 - 0.0138 inch)
No. 2 0.35 - 0.45 mm (0.0138 - 0.0177 inch)
Oil (Side rail) 0.15 - 0.40 mm (0.0059 - 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 - 7.3 mm (0.283 - 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 - 7.6 mm (0.295 - 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 circle 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 - 61.000 mm (2.4011 - 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 crank pin.
Diameter: 52.992 - 53.000 mm (2.0863 - 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 19.0 mm (0.748 inch) and 22.4 mm (0.882 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 claw with the claw groove 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 claw with the claw groove 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 and under the head of bearing cap bolts.
h. Temporarily install the 8 main bearing cap bolts to the inside positions.

i. Insert the main bearing cap with hand until the clearance between the main bearing cap and the cylinder block will become less than 6 mm (0.23 inch) by making the 2 internal bearing cap bolts as a guide.

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 and under the head of main bearing cap bolts.

l. Install and uniformly tighten the 16 main bearing cap bolts in several passes, in the sequence shown.
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 sequence shown.
o. Check that the painted mark is now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.

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

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

q. Remove the main bearing caps.

r. Measure the Plastigage at its widest point.
Standard oil clearance:
No. 1 and No. 4 journals 0.014 - 0.034 mm (0.0006 - 0.0013 inch)
No. 2 and No. 3 journals 0.026 - 0.046 mm (0.0010 - 0.0018 inch)
Maximum clearance:
No. 1 and No. 4 journals 0.05 mm (0.0020 inch)
No. 2 and No. 3 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 using 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. 4 journal bearing sizes, marked "3", "4", "5", "6" and "7" accordingly. The No.2 and No. 3 journal bearings have 5 standard bearing sizes, marked "1", "2", "3", "4" and "5" accordingly.

No. 1 and No. 4 journal bearings

HINT: EXAMPLE
Cylinder block "06" (A) + Crankshaft "08" (B)
=Total number 14 (Use bearing "5")

No. 2 and No. 3 journal bearings

HINT: EXAMPLE
Cylinder block "06" (A) + Crankshaft "08" (B)
=Total number 14 (Use bearing "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-ASSY

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.

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 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Code mark:
No. 1 piston ring T or 1R
No. 2 piston ring 2T or 2R

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

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

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod and let not stick the oils and fats.

39. INSTALL CRANKSHAFT BEARING

HINT: Main bearings come in widths of 19.0 mm (0.748 inch) and 22.4 mm (0.882 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. Clean each main journal and bearing.

b. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

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

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 and under the head of bearing cap bolts.
d. Temporarily install the 8 main bearing cap bolts to the inside positions.

e. Insert the main bearing cap with hand until the clearance between the main bearing cap and the cylinder block will become less than 6 mm (0.23 inch) by making the 2 internal bearing cap bolts as a guide.

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 and under the head of main bearing cap bolts.
h. Install and uniformly tighten the 16 main bearing cap bolts in several passes, in the sequence shown.
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 sequence shown.
k. Check that the painted mark is now at a 90° angle to the front.
l. Check that the crankshaft turns smoothly.

m. Install and uniformly tighten the 8 main bearing cap bolts in several passes, in the sequence shown.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

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

42. INSTALL PISTON SUB-ASSY 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:
- Clean the backside of the bearing and the bearing surface of the connecting rod cap and let not stick the oils and fats.
- Match the numbered connecting rod cap with the connecting rod.

HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".

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

f. Tighten the bolts in several passes by 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 by 90° as shown.
i. Check that the crankshaft turns smoothly.

43. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a 10 mm hexagon wrench, 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 10 mm hexagon wrench, install a new gasket and the screw plug.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)

45. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a 10 mm hexagon wrench, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

46. INSTALL WATER SEAL PLATE
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 3 - 5 mm (0.12 - 0.20 inch)) consequently 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 put into 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-ASSY
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 put into coolant within an 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.