Part 2

Part 1:

Part 2:

CYLINDER BLOCK ASSY
OVERHAUL
26. INSPECT PISTON RING END GAP

a. Using a piston, push the piston ring which it is a little below the bottom of the ring travel, where is 110 mm (4.33 inch) from the top of the cylinder block.

b. Using a feeler gauge, measure the end gap.
Standard end gap:
0.30 to 0.40 mm (0.0118 to 0.0157 inch) for No. 1 ring
0.50 to 0.60 mm (0.0197 to 0.0236 inch) for No. 2 ring
0.15 to 0.40 mm (0.0059 to 0.0157 inch) for oil (side rail) ring
Maximum end gap:
0.95 mm (0.0374 inch) for No. 1 ring
1.05 mm (0.0413 inch) for No. 2 ring
1.00 mm (0.0394 inch) for oil (side rail) ring
^ If the end gap is greater than maximum, replace the piston ring.
^ If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.

27. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 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 to 7.6 mm (0.295 to 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)
If the circle runout is greater than maximum, replace the crankshaft.

b. Using a micrometer, measure the diameter of each main journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 inch)
If the diameter is not as specified, check the crankshaft oil clearance
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)
If the taper and out-of-round is greater than maximum, replace the crankshaft.

d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
If the diameter is not as specified, check the connecting rod oil clearance.
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)
If the taper and out-of-round is greater than maximum, replace the crankshaft.

30. INSPECT CRANKSHAFT OIL CLEARANCE

HINT: Crankshaft bearings come in widths of 22.4 mm (0.882 inch) and 19.0 mm (0.748 inch). Install the 22.4 mm (0.882 inch) bearings in the No. 1 and No. 4 cylinder block journal positions with the bearing caps. 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 key of the bearing with the keyway of the cylinder block, then push in the 4 upper bearings.

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

c. Align the key of the bearing with the keyway of the bearing cap, then 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 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, then install the bearing caps on the cylinder block.
g. Apply a light coat of engine oil to the threads of the bearing cap bolts.

h. Temporarily install the 8 bearing cap bolts to the inside positions.
i. Install the bearing cap by hand using the inner bolt as a guide. Stop when the bearing cap is about 6 mm (0.23 inch) away from contact with the cylinder block.

j. Using a plastic-faced hammer, lightly tap the bearing cap to ensure proper fit.
k. Apply a light coat of engine oil to the threads of the bearing cap bolts.

l. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
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 same sequence as step (1).
o. Check that each painted mark is now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.

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

HINT: Use the short bolt for the position marked with the arrow.

q. Remove the bearing caps.

r. Measure the Plastigage at its widest point.
Standard oil clearance:
0.014 to 0.034 mm (0.0006 to 0.0013 inch) for No. 1 and No. 2 journals
0.026 to 0.046 mm (0.0010 to 0.0018 inch) for No. 3 and No. 4 journals
Maximum clearance:
0.05 mm (0.0020 inch) for No. 1 and No. 2 journals
0.06 mm (0.0024 inch) for No. 3 and No. 4 journals
^ If the oil clearance is greater than maximum, replace the bearings.
^ If necessary, replace the crankshaft.

NOTICE: Completely remove the Plastigage.

s. If replacing 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. 2 journal bearing come in 5 sizes, marked "3", "4", "5", "6" and 7". The No. 3 and No. 4 journal bearings come in 5 standard bearing sizes, marked "'1", "2", "3", "4" and "5".

No. 1 and No. 2 journal bearings

HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked "5" No.

3 and No. 4 journal bearings

HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked "Y

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 the end gap of the snap ring is not aligned with the pin hole cutout of the piston.

35. INSTALL W/PIN PISTON SUB-ASSY

a. Gradually heat the piston up to approximately 80°C (176°F).

b. Coat the piston pin with engine oil.
c. Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin contacts the snap ring.
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 the end of gap of the snap ring is not aligned with the pin hole cutout of the piston.

37. INSTALL PISTON RING SET
a. Install the expander and 2 side rails by hand.

b. Using a piston ring expander, install the 2 compression rings.

HINT: The No. 2 compression ring is installed with the code mark "2A" facing upward as shown in the illustration.

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

NOTICE: Do not align the ring ends.

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

NOTICE: Clean the backside of the bearing and bearing surface of the connecting rod. The surface should be free of dust and oils.

39. INSTALL CRANKSHAFT BEARING

HINT: Crankshaft bearings come in widths of 22.4 mm (0.882 inch) and 19.0 mm (0.748 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 caps. Install the 19.0 mm (0.748 inch) bearings in the No. 2 and No. 3 positions.

a. Clean each main journal and the bearing.

b. Align the key of the bearing with the keyway of the cylinder block, then 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 the upper bearing, then install the crankshaft on the cylinder block.

b. Examine the front marks and numbers, then install the bearing caps on the cylinder block.
c. Apply a light coat of engine oil to the threads of the bearing cap bolts.

d. Temporarily install the 8 bearing cap bolts to the inside positions.
e. Install the bearing cap by hand using the inner bolt as a guide. Stop when the bearing cap is about 6 mm (0.23 inch) away from contact with the cylinder block.

f. Using a plastic-faced hammer, lightly tap the bearing cap to ensure proper fit.
g. Apply a light coat of engine oil to the threads of the bearing cap bolts.

h. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
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 same sequence as step (h).
k. Check that each painted mark is now at a 90° angle to the front.
l. Check that the crankshaft turns smoothly.

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

HINT: Use the short bolt for the position marked with the arrow.

42. INSTALL PISTON SUB-ASSY W/CONNECTING ROD

a. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
b. Check the position of the piston ring ends.
c. Using a piston ring compressor, push the numbered piston and connecting rod assemblies correctly into each cylinder with the front mark of the piston facing forward.

NOTICE: Match the numbered connecting rod cap with the connecting rod.

d. Check that the protrusion of the cap is facing the correct direction.
e. Apply a light coat of engine oil to the threads of the cap bolts.

f. Tighten the cap bolts in several steps by the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

g. Mark the front side of each cap bolt with paint.
h. Retighten the cap bolts by 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.

43. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a socket hexagon wrench 10, 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 socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

45. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
46. INSTALL WATER SEAL PLATE
a. Remove any old seal packing from the contact surface.

b. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 inch)) 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 expose the seal packing to 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 expose the drain cock to coolant within 1 hour after installing.
^ Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque.
^ Do not loosen the drain cock after setting it correctly.