Part 2
OVERHAUL
22. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 - 7.3 mm (0.283 - 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)
b. If the diameter is less than minimum, replace the bolt.
23. INSPECT CRANKSHAFT
a. Using a dial indicator and V-blocks, measure the circle runout, as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
b. Using a micrometer, measure the diameter of each main journal.
Diameter: 54.988 - 55.000 (2.1648 - 2.06535 inch)
c. Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)
HINT:
d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 47.990 - 48.000 mm (1.8894 - 1.8898 inch)
e. Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)
24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 inch)
Minimum diameter: 7.2 mm (0.283 inch)
If the diameter is less than minimum, replace the bolt.
25. INSTALL RING PIN
a. Using a plastic-faced hammer, tap into the ring pin.
Standard protrusion:
Ring pin A 6 mm (0.236 inch)
Ring pin B 5 mm (0.197 inch)
26. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:
- Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
- The bearing cap bolts are tightened in 2 progressive steps.
a. Clean each main journal and bearing.
b. Install the upper bearing with an oil groove on cylinder block.
c. Install the lower bearing on the bearing cap sub assembly.
d. Place the crankshaft on the cylinder block.
e. Lay a strip of plastigage across each journal.
f. Examine the front marks and install the bearing caps on the cylinder block.
g. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
Installation:
h. Tighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
i. Retighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 40 Nm (408 kgf-cm, 29 ft. lbs.)
j. Mark the front of the bearing cap bolts with paint.
k. Retighten the bearing cap bolts by 90° in the numerical order shown.
l. Check that the painted mark is now at a 90° angle to the front.
NOTICE: Do not turn the crankshaft.
m. Remove the bearing cap.
n. Measure the plastigage at its widest point.
Standard oil clearance: 0.017 - 0.040 mm (0.0007 - 0.0016 inch)
Maximum oil clearance: 0.07 mm (0.0028 inch)
NOTICE: Completely remove the plastigage.
o. If using a standard 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 selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
Use:
HINT:
EXAMPLE
Cylinder block "4" (A) + Crankshaft "3" (B) =
Total number 7 (Use bearing "3")
Reference
27. INSTALL TIGHT PLUG
a. Apply adhesive around tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
b. Using SST, into the tight plugs as shown in the illustration.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07100)
Standard depth:
Engine front 1.7 - 2.7 mm (0.067 - 0.106 inch)
Engine rear 2.2 - 3.2 mm (0.087 - 0.126 inch)
28. INSTALL STUD BOLT
a. Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Stud bolt B 10 Nm (97 kgf-cm, 84 inch lbs.)
Stud bolt C 5.0 Nm (51 kgf-cm, 44 inch lbs.)
29. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap into the straight pin.
Standard protrusion
Pin A 7.5 mm (0.295 inch)
Pin B 12 mm (0.472 inch)
30. INSTALL PISTON
a. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
b. Gradually hat the piston to 80 - 90°C (176 - 194°F).
c. Align the front marks on the piston with connecting rod, and push in the piston with your thumb.
d. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
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 with the point mark facing right side.
NOTICE: Install the compression ring No. 2 with the code mark (2N) facing upward.
c. Position the piston rings so that the ring ends are as shown.
32. INSTALL CRANKSHAFT BEARING
a. Install the upper bearing with an oil groove on cylinder block.
NOTICE: Clean the back side of the bearing and the bearing surface of the cylinder block and let not stick the oils and fats.
33. INSTALL CRANKSHAFT BEARING NO. 2
a. Install the lower bearing on bearing cap.
NOTICE: Clean the back side of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
34. INSTALL CRANKSHAFT THRUST WASHER UPPER
a. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
35. INSTALL CRANKSHAFT
a. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
b. Apply engine oil to lower bearing.
c. Examine the front marks and install the bearing caps on the cylinder block.
d. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
Installation:
e. Tighten the blots in several passes, in the sequence shown, by the specified torque.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
f. Tighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 40 Nm (408 kgf-cm, 29 ft. lbs.)
g. Mark the front of the bearing cap bolts with paint.
h. Retighten the bearing cap bolts by 90° in the numerical order shown.
i. Check that the painted mark is now at a 90° angle to the front.
j. Check the crankshaft turns smoothly.
36. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the groove of the connecting rod or connecting cap.
NOTICE: Clean the back side of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
37. INSTALL PISTON
NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps.
a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
b. Check the position of the piston ring ends.
c. 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: Match the numbered connecting rod cap with the connecting rod.
d. Check that the protrusion of the connecting rod cap is facing in the correct direction.
e. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
f. Using a 12 mm socket wrench, tighten the bolts in several passes by the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
g. Mark the front of the connecting cap blots with paint.
h. Retighten the cap bolts by 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.