Part 3

INSPECTION OF CRANKSHAFT

1. INSPECT CRANKSHAFT FOR RUNOUT

(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.08 mm (0.0031 in.)
- If the circle runout is greater than maximum, replace the crankshaft.

2. INSPECT MAIN JOURNALS AND CRANK PINS

(a) Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter: 66.988 - 67.000 mm (2.6373 - 2.6378 in.)
Crank pin diameter: 51.982 - 52.000 mm (2.0465 - 2.0472 in.)
- If the diameter is not as specified, check the oil clearance

(b) Check each main journal and crank pin for taper and out-of-round as shown.

Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
- If the taper or out-of-round is greater than maximum, replace the crankshaft.

REPLACEMENT OF CRANKSHAFT OIL SEALS

NOTE: There are two methods (A and B) to replace the oil seal which are as follows:

1. REPLACE CRANKSHAFT FRONT OIL SEAL

A. If oil pump is removed from cylinder block:

(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge. SST 09316-60010 (09316-00010)
(c) Apply MP grease to the oil seal lip.

B. If oil pump is installed to the cylinder block:

(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.

NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010

ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES

1. ASSEMBLE PISTON AND CONNECTING ROD

(a) Using a small 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) Position the piston front mark with respect to the outside mark on the connecting rod as shown in the diagram.

NOTE: The installation direction of the piston and connecting rod are different for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".

(d) Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
(e) Using a slot screwdriver, install a new snap ring on the other side of the piston pin hole.

2. INSTALL PISTON RINGS

(a) Install the oil ring expander and two side rails by hand.
(b) Using a piston ring expander, install the two compression rings with the code mark facing upward.

Code mark:
No.1 1R or T
No.2 2R or 2T

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

NOTE: Do not align the piston ring ends.

3. INSTALL BEARINGS

(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.

ASSEMBLY OF CYLINDER BLOCK

NOTE: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, 0-rings and oil seals with new parts.

1. INSTALL MAIN BEARINGS

NOTE: Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No.1 and No.5 cylinder block journal positions with the main bearing caps. Install the 1 9.5 mm (0.768 in.) bearings in the o
ther 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 five upper bearings.
(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the five lower bearings.

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

2. INSTALL UPPER THRUST WASHERS
- Install the two thrust washers under the No.3 journal position of the block with the oil grooves facing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAP AND LOWER THRUST WASHERS

A. Place main bearing cap and lower thrust washers on cylinder block

(a) Install the two thrust washers on the No.3 main bearing cap with the grooves facing outward.

(b) Install the main bearing caps in their proper locations.
(c) Place the five bearing caps in position on cylinder block.

NOTE: Place the bearing caps level and let them return to their original position by their own weight. Do not install the main bearing cap by tapping it.

B. Install main bearing cap nuts

NOTE: The main bearing cap nuts are tightened in two progressive steps.If any main bearing cap stud bolt is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the nuts of the main bearing caps.

(b) Install and uniformly tighten the twenty main bearing cap nuts in several passes, in the sequence shown.

Torque: 27 N.m (275 kgf.cm, 20 ft.lb)

- If any one of the main bearing cap nuts does not meet the torque specification, replace the main bearing cap stud bolt.

(c) Mark the front of the main bearing cap nut with paint.
(d) Retighten the main bearing cap nuts 900 in the numerical order shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance.

C. Install main bearing cap bolts

(a) Install a new seal washer to the main bearing cap bolt.

(b) Install the ten main bearing cap bolts.

Torque: 49 N.m (500 kgf.cm, 36 ft.lb)

5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES

- 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.

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

6. INSTALL CONNECTING ROD CAPS

A. Place connecting rod cap on connecting rod

(a) Match the numbered connecting rod cap with the connecting rod.
(b) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.

(c) Check that the outside mark on the connecting rod cap is facing in the correct direction.

B. Install connecting rod cap bolts

NOTE: The connecting rod cap bolts are tightened in two progressive steps. If any connecting rod bolt is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the two connecting rod cap bolts in several passes.

Torque: 25 N.m (250 kgf.cm, 18 ft.lb)
- If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolt.

(c) Mark the front of the connecting rod cap bolt with paint.
(d) Retighten the connecting rod cap bolts 90° in the numerical order shown.
(e) Check that the painted mark is now at a 90° angle to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance.

7. INSTALL REAR OIL SEAL RETAINER

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the retainer as shown in the illustration.Seal packing: Part No.08826-00080 or equivalent. Install a nozzle that has been cut to a 2 - 3 mm (0.08-0.12 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

(d) Install the retainer with the seven bolts.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lb)

POST ASSEMBLY

1. INSTALL WATER SEAL PLATE

(a) Remove any old packing (FIPG) material.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the seal plate as shown in the illustration. Seal packing: Part No.08826-00100 or equivalent. Install a nozzle that has been cut to a 2 - 3 mm (0.08-0.12 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

(C) Install the seal plate with the two nuts.

Torque: 14 N.m (145 kgf.cm, 10 ft.lb)

2. INSTALL ALTERNATOR BRACKET
- Install the bracket with the bolt.

Torque: 18 N.m (185 kgf.cm, 13 ft.lb)

3. INSTALL OIL PUMP

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No.08826-00080 or equivalent.Install a nozzle that has been cut to a 2 - 3 mm (0.08-0.12 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

(d) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide on the oil pump.
(e) Install the oil pump with the eight bolts.

Torque:

12 mm head 16 N.m (160 kgf.cm, 12 ft.lb)
14 mm head 30 N.m (310 kgf.cm, 22 ft.lb)

NOTE: Each bolt length is indicated in the illustration.

Bolt length:

A 50 mm (1.97 in.) for 12 mm head
B 106 mm (4.17 in.) for 12 mm head
C 30 mm (1.18 in.) for 12 mm head
D 40 mm (1.57 in.) for 14 mm head

4. INSTALL NO.1 OIL PAN

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan, cylinder block, oil pump and rear oil seal retainer. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No.08826-00080 or equivalent.Install a nozzle that has been cut to a 2 - 3 mm (0.08-0.12 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

(c) Place the oil pan in position on the cylinder block.

NOTE: Make sure the clearance between the oil pan end and cylinder block end is 0.2 mm or less (0.008 in.). If the clearance is more than 0.2 mm (0.008 in.). the oil pan will be stretched.

(d) Install the oil pan with the eighteen bolts and two nuts.

Torque:

10 mm head 7.8 N.m (80 kgf.cm, 69 in.lb)
12 mm head 18 N.m (185 kgf.cm, 13 ft.lb)

NOTE: Each bolt length is indicated in the illustration.

Bolt length:

A 20 mm (0.78 in.) for 10 mm head
B 35 mm (1.38 in.) for 10 mm head
C 55 mm (2.17 in.) for 12 mm head

5. INSTALL OIL STRAINER
6. INSTALL OIL PAN BAFFLE PLATE
7. INSTALL NO.2 OIL PAN
8. INSTALL WATER PUMP
9. INSTALL WATER BY-PASS PIPE

(a) Install a new 0-ring to the by-pass pipe.
(b) Apply soapy water to the 0-ring.
(c) Pull in the by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the two bolts.

Torque: 18 N.m (185 kgf.cm, 13 ft.lb)

10. INSTALL KNOCK SENSORS
- Using SST, install the two knock sensors. SST 09816-30010

Torque: 44 N.m (450 kgf.cm, 33 ft.lb)

11. INSTALL ENGINE WIRE

(a) Install the engine wire to the RH side of the cylinder block with the wire clamp and bolt.
(b) Install the engine wire to the LH side of the cylinder block with the two wire clamps and bolts.
(c) Install the wire cover to the LH side of the cylinder block with the two bolts.
(d) Connect the following connectors:

(1) Two knock sensor connectors
(2) Oil pressure switch connector

12. INSTALL STARTER

(a) Connect the connector to the starter.
(b) Connect the wire to the starter with the nut.
(c) Install the starter with the two bolts.

Torque: 39 N.m (400 kgf.cm, 29 ft.lb)

13. INSTALL RH ENGINE MOUNTING BRACKET
- Install the mounting bracket with the four bolts.

Torque: 37 N.m (380 kgf.cm, 27 ft.lb)

NOTE: The RH mounting bracket is marked with "R".

14. INSTALL LH ENGINE MOUNTING BRACKET
- Install the mounting bracket with the four bolts.

Torque: 37 N.m (380 kgf.cm, 27 ft.lb)

NOTE: The LH mounting bracket is marked with "L".

15. INSTALL CYLINDER HEADS
16. INSTALL TIMING PULLEYS AND BELT
17. REMOVE ENGINE STAND FROM ENGINE
18. INSTALL DRIVE PLATE

(a) Apply adhesive to two or three threads of the bolt end. Adhesive: Part No.08833-00070 THREE BOND 1324 or equivalent
(b) Install the front spacer, drive plate and rear spacer on the crankshaft.

(c) Install and uniformly tighten the eight mounting bolts in several passes, in the sequence shown.

Torque: 98 N.m (1,000 kgf.cm. 72 ft.lb)