Part 2

CYLINDER BLOCK ASSEMBLY
OVERHAUL
21. 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 0.22 to 0.32 mm (0.0087 to 0.0126 inch)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 inch)
Oil (side rail) 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
Maximum end gap:
No. 1 0.89 mm (0.0350 inch)
No. 2 1.35 mm (0.0531 inch)
Oil (side rail) 0.73 mm (0.0287 inch)
If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block.
22. INSPECT PISTON PIN OIL CLEARANCE

a. Using a caliper gauge, measure the inside diameter of the piston bushing.
Pin hole bush diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 inch)

Pin hole bush diameter (Reference)

b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.009 mm (0.8660 to 0.8665 inch)

Piston pin diameter (Reference)

c. Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Bush inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)

Bush inside diameter

d. Subtract the piston pin diameter measurement from the piton pin bush hole diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 inch)
Maximum oil clearance: 0.010 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.

If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
e. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.010 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
23. INSPECT CONNECTING ROD SUB-ASSEMBLY
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.

1. Check for out-of-alignment.
Maximum out-of-alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the out-of-alignment is greater than the maximum, replace the connecting rod assembly.

2. Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than the maximum, replace the connecting rod assembly.

24. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 inch)
Maximum diameter: 7.0 mm (0.276 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 circle runout, as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than the maximum, replace the crankshaft.

b. Using a micrometer, measure the diameter of each main journal.
Diameter: 54.988 to 55.000 mm (2.16488 to 2.16535 inch)
If the diameter is not as specified, check the oil clearance (see step 26). If necessary, replace the crankshaft.
c. Check each main journal for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

Diameter (Reference)

d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 inch)
If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft.
e. Check each crank pin for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

26. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.3 to 7.6 mm (0.287 to 0.299 inch)
Minimum diameter: 7.2 mm (0.283 inch)
If the diameter is less than the minimum, replace the bolt.

27. INSTALL RING PIN
a. Using a plastic-faced hammer, tap into the ring pin.

28. INSTALL TIGHT PLUG
a. Apply adhesive around the tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
b. Using SST, install new tight plugs as shown in the illustration.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07100)

29. INSTALL STUD BOLT
a. Install the stud bolts as shown in the illustration.
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for stud bolt A
10 Nm (102 kgf-cm, 7 ft. lbs) for stud bolt B
5.0 Nm (51 kgf-cm, 44 inch lbs.) for stud bolt C

30. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap into the straight pin.
31. INSTALL PISTON

a. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
b. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

c. Align the front marks of the piston and 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.
32. 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 painted mark as shown in the illustration.

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 in the illustration.

33. INSTALL CRANKSHAFT BEARING
a. Install the upper bearing with an oil groove on the cylinder block.

NOTICE: Clean the contact surfaces of the bearing and the cylinder block. The surfaces should be free of dust and oils.

34. INSTALL CRANKSHAFT BEARING NO.2
a. Install the lower bearing on bearing cap.

NOTICE: Clean the contact surfaces of the bearing and the bearing cap. The surfaces should be free of dust and oils.

35. 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.
36. INSTALL CRANKSHAFT
a. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
b. Examine the front marks and numbers and install the bearing caps on the cylinder block.
c. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts.

d. Install and uniformly tighten 10 main bearing cap bolts in several passes, in the sequence shown.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)

e. Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the sequence shown.
g. Check that the painted mark is now at a 90° angle to the front.
h. Check that the crankshaft turns smoothly.
37. 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. The surface should be free of dust and oil.

38. 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.
Using a 12 mm socket wrench, uniformly tighten the 2 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
g. Mark the front of the connecting cap bolts with paint.

h. Retighten the cap bolts 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.
SST 09011-38121