Part 2
OVERHAUL (CONTINUED)
21. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.
Ring groove clearance:
No.1 0.02 to 0.07 mm (0.0008 to 0.0028 inch
No.2 0.02 to 0.06 mm (0.0008 to 0.0024 inch)
Oil 0.07 to 0.15 mm (0.0028 to 0.0060 inch)
22. INSPECT PISTON RING END GAP
a. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.
b. Using a feeler gauge, measure the end gap.
Standard end gap:
No.1 0.30 to 0.40 mm (0.0118 to 0.0157 inch)
No.2 0.40 to 0.50 mm (0.0157 to 0.0197 inch)
Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 inch)
Maximum end gap:
No.1 1.0 mm (0.039 inch)
No.2 1.1 mm (0.043 inch)
Oil (Side rail) 1.0 mm (0.039 inch)
23. 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 the minimum, replace the bolt.
24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 10.0 to 10.2 mm (0.393 to 0.402 inch)
If the diameter is less than the minimum, replace the bolt.
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 to 72.000 mm (2.8342 to 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 to 56.000 mm (2.2044 to 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 22.4 mm (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 or 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 or 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 to the threads of the 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 less than 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 to the threads of the 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 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: 26 Nm (262 kgf-cm, 19 ft. lbs.)
q. Remove the main bearing caps.
r. Measure the Plastigage at its widest point.
Standard oil clearance: 0.018 to 0.030 mm (0.0007 to 0.0012 inch)
Maximum clearance: 0.046 mm (0.0018 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
NOTICE: Completely remove the Plastigage.
s. If replacing a bearing, replace it with one that has 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 appropriate bearing number. There are 5 sizes 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:
11 Nm (112 kgf-cm, 8.1 ft. lbs.) for stud bolt A
4.5 Nm (46 kgf-cm, 40 inch lbs.) for stud bolt B
4.0 Nm (41 kgf-cm, 35 inch lbs.) for stud bolt C
28. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap in the straight pin.
Standard protrusion:
22.5 to 23.5 mm (0.886 to 0.925 inch) for pin A
10.5 to 11.5 mm (0.413 to 0.453 inch) for pin B
8.5 to 9.5 mm (0.335 to 0.374 inch) for pin C
5.5 to 6.5 mm (0.217 to 0.256 inch) for pin D
29. INSTALL TIGHT PLUG
a. Apply adhesive around the 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 to 1.2 mm (0.008 to 0.047 inch)
30. INSTALL OIL JET
a. Using a screwdriver and hemmer, tap in the oil jet.
31. INSTALL SUB-ASSEMBLY 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 screwdriver, install a new snap ring on 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-ASSEMBLY
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 a thumb.
34. INSTALL PISTON PIN HOLE SNAP RING
a. Using a screwdriver, install a new snap ring on the other side of the piston pin hole.
HINT: Be sure that an end 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 contact surface of the connecting rod and prevent oil from adhering to them.
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 22.4 mm (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: The number marked on each main bearing cap indicates the installation position.
38. INSTALL CRANKSHAFT
a. Apply engine oil to the 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 to the threads of the 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 less than 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 to the threads of the 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: 26 Nm (262 kgf-cm, 19 ft. lbs.)
39. INSTALL PISTON SUB-ASSEMBLY W/CONNECTING ROD
a. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
b. Check the positions 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 contact surface of the connecting rod cap and prevent oil from adhering to them.
^ 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 to the threads of the connecting rod cap bolts.
f. Using SST, tighten the bolts alternately with the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
g. Mark the front side of each connecting cap bolt with paint.
h. Retighten the cap bolts 90° as shown.
i. Check that the crankshaft turns smoothly.