Part 2

OVERHAUL (CONTINUED)

23. INSPECT CRANKSHAFT OIL CLEARANCE

NOTICE: Main bearings come in widths of 18.0 mm (0.709 inch) and 21.0 mm (0.827 inch). Install the 21.0 mm (0.827 inch) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 inch) bearings in the No.2 and No.3 positions.

a. Clean the main journal and 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 and its contact surface.

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): 0.7 mm (0.0276 inch) or less

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

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.

HINT: A number is marked on each main bearing cap to indicate the installation position.

g. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
h. Temporarily install the 8 main bearing cap bolts to the inside positions.

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

HINT: Bolt length: 100 to 102 mm (3.94 to 4.02 inch)

j. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
k. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

l. Install the 8 main bearing cap bolts to the outside positions.

HINT: Bolt length: 105.5 to 107.5 mm (4.15 to 4.23 inch)

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

n. Mark the front side of the bearing cap bolts with paint.
o. Tighten the bearing cap bolts another 90° in the sequence shown.
p. Check that the painted mark is now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.

q. Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 52 Nm (525 kgf-cm, 38 ft. lbs.)

HINT:
- Bolt (A) length: 45 mm (1.77 inch)
- Except bolt (A) length: 30 mm (1.18 inch)

r. Remove the main bearing caps (see step 6)

s. Measure the Plastigage at its widest point.
Standard oil clearance: 0.026 to 0.047 mm (0.0010 to 0.0019 inch)
Maximum clearance: 0.050 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTICE: Completely remove the Plastigage.

t. If using a bearing, replace it with one that has 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 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly

Journal bearings

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

24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
Standard diameter: 10.8 to 11.0 mm (0.4252 to 0.4331 inch)
Minimum diameter: 10.7 mm (0.4213 inch)
If the diameter is less than the minimum, replace the bolt.
25. 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, tap in the tight plugs.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07100)

26. INSTALL STRAIGHT PIN
a. Using a plastic hammer, tap in new straight pins to the cylinder block.
Standard protrusion:
Pin A: 23 mm (0.906 inch)
Pin B: 6 mm (0.236 inch)
Pin C: 11 mm (0.433 inch)
Pin D: 9 mm (0.354 inch)

27. INSTALL STUD BOLT
a. Using an E8 Torx socket wrench, install the stud bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

28. INSTALL SUB-ASSEMBLY OIL NOZZLE NO.1
a. Using a 5 mm hexagon wrench, install the 3 oil nozzles with the bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
29. 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 18) 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.
30. INSTALL PISTON SUB-ASSEMBLY WITH PIN

a. Using a 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.

1. Gradually heat the piston to approximately 80°C (176°F),

2. Coat the piston pin with engine oil.
3. 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.

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

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

HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

31. 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 so that the painted marks are positioned as shown in the illustration.

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

NOTICE: Do not align the ring ends.

32. INSTALL CRANKSHAFT BEARING

NOTICE: Main bearings come in widths of 18.0 mm (0.709 inch) and 21.0 mm (0.827 inch). Install the 21.0 mm (0.827 inch) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 inch) bearings in the No.2 and No.3 positions.

a. Clean the main journal, and 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 and its contact surface.

a. Install the crankshaft thrust washer to the cylinder block.
1. Install the 2 thrust washers under the No.2 journal position of the cylinder block with the oil grooves facing outward.
b. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

c. Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT: A number is marked on each main bearing cap to indicate the installation position.

d. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

e. Temporarily install the 8 main bearing cap bolts to the inside positions.

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

HINT: Bolt length: 100 to 102 mm (3.94 to 4.02 inch)

g. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
h. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

i. Install the 8 main bearing cap bolts to the outside positions.

HINT: Bolt length: 105.5 to 107.5 mm (4.15 to 4.23 inch)

j. Install the crankshaft bearing cap bolts.

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

k. Step 1
1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)
If any of the main bearing cap bolts does not meet the torque specification, replace it.

l. Step 2
1. Mark the front of the bearing cap bolts with paint.
2. Tighten the bearing cap bolts another 90° in the order above.
3. Check that the painted mark is now at a 90° angle to the front.
m. Check that the crankshaft turns smoothly.
n. Check the crankshaft thrust clearance (see step 5).

o. Install and uniformly tighten the 8 main bearing cap bolts in several steps and, in the sequence shown in the illustration.
Torque: 52 Nm (525 kgf-cm, 38 ft. lbs.)

HINT:
- Bolt (A) length: 45 mm (1.77 inch)
- Except bolt (A) length: 30 mm (1.18 inch)

p. Check that the crankshaft turns smoothly.
q. Check the crankshaft thrust clearance (see step 5).

34. INSTALL CONNECTING ROD BEARING
a. Install the connecting rod bearing to the connecting rod and bearing cap.
b. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge.
Dimension (A - B): 0.7 mm (0.0276 inch) or less

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

35. INSTALL PISTON SUB-ASSEMBLY W/CONNECTING ROD
a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the 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 the connecting cap bolts.

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

h. Step 1
1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
SST 09011-38121
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

i. Step 2
1. Mark the front side of each connecting cap bolt with paint.
2. Tighten the cap bolts another 90° as shown in the illustration.
3. Check that the painted mark is now at a 90° angle to the front.
j. Check that the crankshaft turns smoothly.
k. Check the connecting rod thrust clearance (see step 1).