Part 2

OVERHAUL





25. INSPECT CRANKSHAFT
a) Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 inch)





b) Using a micrometer, measure the diameter of each main journal.
Diameter: 71.988 - 72.000 mm (2.8342 - 2.8346 inch)
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)





d) Using a micrometer, measure the diameter of each crank pin.
Diameter: 55.992 - 56.000 mm (2.2044 - 2.2047 inch)
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)





26. INSPECT CRANKSHAFT OIL CLEARANCE

HINT: Main bearings come in widths of 19.0 mm (0.748 inch) and 22.4 mm (0.882 inch). Install the 22.4mm (0.882 inch) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. 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 bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

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





c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 bottom bearings.

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

HINT: A number marked on each main bearing cap indicates 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 and install the bearing caps on the cylinder block.
g) Apply a light coat of engine oil on the threads of bearing cap bolts.
h) Temporarily install the 8 main bearing cap bolts to the inside positions.





i) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes under 6 mm (0.23 inch).





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





l) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)





m) Mark the front side of the bearing cap bolts with paint.
n) Retighten the bearing cap bolts until 90° in the sequence as shown
o) Check that the painted mark is now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.





p) Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
q) Remove the main bearing caps.





r) Measure the Plastigage at its widest point.
Standard oil clearance: 0.018 - 0.030 mm (0.0007 - 0.0012 inch)
Maximum clearance: 0.046 mm (0.0018 inch)
If the oil clearance is greater than maximum, replace the bearings.
If necessary, replace the crankshaft.

NOTICE: Completely remove the plastigage.





s) If using 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. There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5" accordingly





Journal bearings





HINT:
EXAMPLE
Cylinder block"11" (A) + Crankshaft "06" (B)
=Total number 17 (Use bearing "3")





27. INSTALL STUD BOLT
a) Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A 11 Nm (112 kgf-cm, 8.1 ft. lbs.)
Stud bolt B 4.5 Nm (46 kgf-cm, 40 inch lbs.)
Stud bolt C 4.0 Nm (41 kgf-cm, 35 inch lbs.)





28. INSTALL STRAIGHT PIN
a) Using a plastic-faced hammer, tap into the straight pin.
Standard protrusion:
Pin A 22.5 - 23.5 mm (0.886 - 0.925 inch)
Pin B 10.5 - 11.5 mm (0.413 - 0.453 inch)
Pin C 8.5 - 9.5 mm (0.335 - 0.374 inch)
Pin D 5.5 - 6.5 mm (0.217 - 0.256 inch)





29. INSTALL TIGHT PLUG
a) Apply adhesive around tight plugs.
Adhesive: part No.08833-00070, THREE BOND 1324 or equivalent.
b) Using SST, install the tight plugs as shown in the illustration.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07150)
Standard depth: 0.2 - 1.2 mm (0.008 - 0.047 inch)





30. INSTALL OIL JET
a) Using a screwdriver and hammer, tap in a oil jet.





31. INSTALL SUB-ASSY OIL NOZZLE NO.1
a) Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 Nm(92 kgf-cm, 80 inch lbs.)





32. INSTALL PISTON PIN HOLE SNAP RING
a) Using a small screwdriver, install a new snap ring at one side of the piston pin hole.

HINT: Check that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.





33. INSTALL W/PIN PISTON SUB-ASSY
a) Gradually heat the piston to about 80°C (176°F).





b) Coat the piston pin with engine oil.
c) Align the front marks of the piston and connecting rod, and push in the piston pin with thumb.





34. INSTALL PISTON PIN HOLE SNAP RING
a) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

HINT: Be sure that an end of gap of the snap ring is not overlapped
to the pin hole cutout portion of the piston.





35. 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.

NOTICE: Install the compression ring No. 2 with the painted mark facing upward.





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





36. INSTALL CONNECTING ROD BEARING
a) Align the bearing claw with the groove of the connecting rod or connecting cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod and let not stick the oils and fats.





37. INSTALL CRANKSHAFT BEARING

HINT: Main bearings come in widths of 19.0 mm (0.748 inch) and 22.4 mm (0.882 inch). Install the 22.4mm (0.882 inch) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. 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 bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

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





c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

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

HINT: A number marked on each main bearing cap indicates installation position.

38. INSTALL CRANKSHAFT
a) Apply engine oil to upper bearing and install the crankshaft on the cylinder block.





b) Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block.
1) Push the crankshaft toward the front (rear) side.
2) Install the 2 upper thrust washers with the oil grooves facing outward.





c) Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward.





d) Examine the front marks and numbers and install the bearing caps on the cylinder block.
e) Apply a light coat of engine oil on the threads of bearing cap bolts.
f) Temporarily install the 8 main bearing cap bolts to the inside positions.





g) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes under 6 mm (0.23 inch).





h) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
i) Apply a light coat of engine oil on the threads of main bearing cap bolts.





j) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)





k) Mark the front side of the bearing cap bolts with paint.
l) Retighten the bearing cap bolts 90° in the sequence as shown.
m) Check that the painted mark is now at a 90° angle to the front.
n) Check that the crankshaft turns smoothly.





o) Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence as shown in the illustration.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)





39. INSTALL PISTON SUB-ASSY W/CONNECTING ROD
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:
- Clean the backside of the bearing and the bearing surface of the connecting rod cap and let not stick the oils and fats.
- Match the numbered connecting rod cap with the connecting rod.





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





f) Using SST, tighten the bolts alternately with the specified torque.
SST 09011-38121
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





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