Part 2
OVERHAUL
16. INSPECT CRANKSHAFT BEARING CAP BOLT
a. Using vernier calipers, measure the tension portion diameter of the main bearing cap bolt.
Standard diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 inch)
Minimum diameter: 7.20 mm (0.2835 inch)
If the diameter is less than minimum, replace the cap bolt.
17. INSPECT CRANKSHAFT
a. Inspect for circle runout.
1. Place the crankshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.08 mm (0.0031 inch)
If the circle runout is greater than maximum, replace the crankshaft.
b. Inspect the main journals and crank pins.
1. 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 inch)
Crank pin diameter: 51.982 - 52.000 mm (2.0465 - 2.0472 inch)
If the diameter is not as specified, check the oil clearance (See steps 4 and 8). If necessary, replace the crankshaft.
2. 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 inch)
If the taper and out-of-round is greater than maximum, replace the crankshaft.
18. INSTALL STUD BOLT
19. INSTALL STRAIGHT PIN
20. INSTALL RING PIN
21. INSTALL CONNECTING ROD SMALL END BUSH
a. Align the oil holes of a new bushing and the connecting rod.
b. Using SST and a press, press in the bushing.
SST 09222-30010
c. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See step 13) between the bushing and piston pin.
d. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
22. INSTALL W/ PIN PISTON SUB-ASSY
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. 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 diagram.
NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "3L", the RH piston with "3R".
e. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
f. Check fit between the piston and piston pin.
1. Try to move the piston back and forth on the piston pin.
g. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
h. Install the oil ring expander and 2 side rails by hand.
i. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Code mark
j. Position the piston rings so that the ring ends are as shown.
NOTICE: Do not align the ring ends.
23. 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.
24. 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.
25. 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.
26. 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 position 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 (steps (2) and (4)).
^ If any one of the bearing cap bolts is broken or deformed, replace it.
1. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
2. Install and uniformly tighten the 20 crankshaft bearing cap bolts in several passes, in the sequence shown.
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 bolt with paint.
4. Retighten the crankshaft bearing cap bolts by 90° in the numerical order shown.
5. Check that the painted mark is now at a 90° angle to the front.
6. Install a new seal washer to the crankshaft bearing cap bolt.
7. Install and uniformly tighten the 10 crankshaft bearing cap bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
d. Check that the crankshaft turns smoothly.
e. Check the crankshaft thrust clearance (See step 7).
27. 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 "3L", the RH piston with "3R".
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 correct direction.
c. Install the connecting rod cap bolts.
HINT:
^ The connecting rod cap bolts are tightened in 2 progressive steps (steps (2) and (4)).
^ If any one of the connecting rod cap bolts is broken or deformed, replace it.
1. Apply a light coat of engine oil on 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 passes.
Torque: 24.5 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.
5. Check that the painted mark is now at a 90° angle to the front.
d. Check that the crankshaft turns smoothly.
e. Check the connecting rod thrust clearance (See step 3).
28. INSTALL WATER SEAL PLATE
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the seal plate 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 seal plate 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 inch) 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 2 nuts. Alternately tighten the nuts in several passes.
Torque: 14 Nm (145 kgf-cm, 10 ft. lbs.)
29. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent
b. Install the RH and LH drain unions.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.