Part 3

OVERHAUL (CONTINUED)





21. INSTALL STRAIGHT PIN





22. INSTALL RING PIN
23. INSTALL PISTON





a. Using a screwdriver, install a new snap ring on one side of the piston pin hole.





b. Gradually heat the piston to about 60°C (140°F).





c. Coat the piston pin with engine oil.
d. Position the piston front mark with respect to the outside mark on the connecting rod as shown in the illustration.

NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with 1 cavity and 2, the RH piston with 2 cavities and 2.

e. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.





f. Using a screwdriver, install a new snap ring on the other side of the piston pin hole.
24. 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 piston rings with the code mark facing upward.





Code mark





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

NOTICE: Do not align the ring ends.





25. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the groove of the connecting rod or connecting cap.
b. Install the bearings in the connecting rod and connecting rod cap.





26. INSTALL CRANKSHAFT BEARING

HINT:
^ Main bearings come in widths of 19.5 mm (0.768 inch) and 22.5 mm (0.886 inch). Install the 22.5 mm (0.886 inch) bearings in the No.1 and No.5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 inch) bearings in the other positions.
^ Upper bearings have an oil groove and oil holes; lower bearings do not.





a. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.





b. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

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

27. INSTALL CRANKSHAFT THRUST WASHER SET





a. Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.





b. Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
28. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
29. INSTALL CRANKSHAFT





a. Place the crankshaft on the cylinder block.
b. Install the 5 crankshaft bearing caps in their proper locations.

HINT: Place the bearing caps level and let them return to their original positions by their own weight.

NOTICE: Do not install the bearing cap by tapping it.





c. Install the crankshaft bearing cap bolts.

HINT:
^ The bearing cap bolts are tightened in 2 progressive steps.
^ If any one of the bearing cap bolts is broken or deformed, replace it.

1 Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
2 Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.





3 Mark the front of the crankshaft bearing cap bolts with paint.
4 Retighten the crankshaft bearing cap bolts by 90° in the order shown.
5 Check that the painted mark is now at a 90° angle to the front.
6 Check that the crankshaft turns smoothly.
30. INSTALL PISTON AND CONNECTING ROD





a. 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: The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and 2, the RH piston with 2 cavities and 2.





b. Place the connecting rod cap on the connecting rod.
1 Match the numbered connecting rod cap with the connecting rod.
2 Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.





3 Check that the outside mark of the connecting rod cap is facing in the correct direction.





c. Install the connecting rod cap bolts.

HINT:
^ The connecting rod cap bolts are tightened in 2 progressive steps.
^ If any one of the connecting rod cap bolts is broken or deformed, replace it.

1 Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
2 Install and alternately tighten the 2 connecting rod cap bolts in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.





3 Mark the front of the connecting cap bolt with paint.
4 Retighten the cap bolts 90° as shown in the illustration.
5 Check that the painted mark is now at a 90° angle to the front.
d. Check that the crankshaft turns smoothly.