Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

INSPECTION(continued)

23. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Standard ring groove clearance:

24. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.

(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.

Standard end gap:

Maximum end gap:

25. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.

(1) Check for bend.
Maximum bend: 0.05 mm (0.00197 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum, replace the connecting rod sub-assembly.

(2) Check for twist.
Maximum twist: 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod sub-assembly.

26. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.00236 in.)
If the circle runout is greater than the maximum, replace the crankshaft.

(b) Using a micrometer, measure the diameter of each main journal.
Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(c) Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.000787 in.)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

(d) Using a micrometer, measure the diameter of each crank pin.
Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(e) Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.000787 in.)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.
27. INSPECT CRANKSHAFT THRUST CLEARANCE

28. INSPECT CRANKSHAFT OIL CLEARANCE

HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) 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 bearings and the contact surfaces.
^ Do not allow coolant to come into contact with the bearing inner surface.
^ If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

(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 bearings and the contact surfaces.
^ Do not allow coolant to come into contact with the bearing inner surface.
^ If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

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 crankshaft bearing caps on the cylinder block.
(g) Temporarily install the 8 crankshaft bearing cap bolts to the inside positions.

(h) Tighten the 2 bolts for each bearing cap until the clearance between the crankshaft bearing cap and the cylinder block becomes less than 6 mm (0.236 in.).

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

(k) Step 1:
(1) Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps in the order shown in the illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)

(l) Step 2:
(1) Mark the front side of the crankshaft bearing cap bolts with paint.
(2) Tighten the bearing cap bolts another 90° in the order shown in step 1.
(m) Check that the painted marks are now at a 90° angle to the front.

NOTICE: Do not turn the crankshaft.

(n) Install and uniformly tighten the 8 crankshaft bearing cap bolts in several steps in the sequence shown in the illustration.
Torque: 26 N*m (262 kgf*cm, 19 ft.*lbf)

(o) Remove the crankshaft bearing caps.
(1) Step 1: Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.

(2) Step 2: Uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.

(p) Measure the Plastigage at its widest point.
Standard oil clearance: 0.018 to 0.030 mm (0.000709 to 0.00118 in.)
Maximum clearance: 0.046 mm (0.00181 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTICE: Completely remove the Plastigage.

(q) 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 the 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")

Standard journal diameter (Part 1):

Standard journal diameter (Part 2):

Standard bearing center wall thickness:

29. INSPECT CONNECTING ROD THRUST CLEARANCE
30. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Install the crankshaft bearing.
(b) Install the crankshaft.

(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) Step 1:
(1) Install and uniformly tighten the connecting rod cap bolts in sequence.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)

(g) Step 2:
(1) Mark the front side of each connecting rod cap bolt with paint.
(2) Tighten the bearing cap bolts in step 1 another 90°.
(h) Remove the 2 bolts, connecting rod cap and lower bearing.

(i) Measure the Plastigage at its widest point.
Standard oil clearance: 0.026 to 0.046 mm (0.00102 to 0.00181 in.)
Maximum oil clearance: 0.066 mm (0.00260 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTICE: Completely remove the Plastigage.

(j) If replacing a bearing, replace it with one that has the same number marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

Standard bearing center wall thickness (Part 1):

Standard bearing center wall thickness (Part 2):

(k) Remove the crankshaft.
(l) Remove the crankshaft bearing.

31. INSPECT NO. 1 CHAIN
(a) Using a spring scale, pull the No. 1 chain with a force of 147 N (15 kgf, 33.1 lbf) and measure the length of the No. 1 chain by using a vernier caliper.
Maximum chain elongation: 146.8 mm (5.78 in.)

NOTICE: Perform the measurement at 3 random places. If a measurement is greater than the maximum, replace the No. 1 chain.

32. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Using a spring scale, pull the No. 2 chain with a force of 147 N (15 kgf, 33.1 lbf) and measure the length of the No. 2 chain by using a vernier caliper.
Maximum chain elongation: 146.8 mm (5.78 in.)

NOTICE: Perform the measurement at 3 random places. If a measurement is greater than the maximum, replace the No. 2 chain.

33. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Wrap the No. 1 chain around the gear place for the No. 1 chain.
(b) Using a vernier caliper, measure the timing gear with the No. 1 chain.
Minimum gear diameter (with chain): 115.5 mm (4.55 in.)

HINT: The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the No. 1 chain and camshaft timing gear assembly.

(c) Wrap the No. 2 chain around the gear place for the No. 2 chain.
(d) Using a vernier caliper, measure the timing gear with the No. 2 chain.
Minimum gear diameter (with chain): 73.1 mm (2.88 in.)

HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the No. 2 chain and camshaft timing gear assembly.

34. INSPECT CAMSHAFT TIMING SPROCKET
(a) Wrap the No. 2 chain around the sprocket.
(b) Using a vernier caliper, measure the camshaft timing sprocket diameter with the No. 2 chain.
Minimum gear diameter (with chain): 73.1 mm (2.88 in.)

HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the No. 2 chain and camshaft timing sprocket.

35. INSPECT CRANKSHAFT TIMING SPROCKET
(a) Wrap the No. 1 chain around the sprocket.
(b) Using a vernier caliper, measure the crankshaft timing sprocket diameter with the No. 1 chain.
Minimum gear diameter (with chain): 61.0 mm (2.40 in.)

HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the No. 1 chain and crankshaft timing sprocket.

36. INSPECT NO. 1 IDLE GEAR
(a) Wrap the No. 1 chain around the gear.
(b) Using a vernier caliper, measure the No. 1 idle gear with the No. 1 chain.
Minimum gear diameter (with chain): 61.0 mm (2.40 in.)

HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the No. 1 chain and No. 1 idle gear.

37. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE
(a) Using a micrometer, measure the No. 1 idle gear shaft diameter.
Standard idle gear shaft diameter: 22.987 to 23.000 mm (0.905 to 0.906 in.)

(b) Using a caliper gauge, measure the inside diameter of the idle gear.
Standard idle gear inside diameter: 23.02 to 23.03 mm (0.906 to 0.907 in.)
(c) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.
Standard oil clearance: 0.020 to 0.043 mm (0.000787 to 0.00169 in.)
Maximum oil clearance: 0.093 mm (0.00366 in.)
If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear.

38. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the chain tensioner assembly.

39. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth: 1.0 mm (0.0394 in.)
If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly.

40. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth: 1.0 mm (0.0394 in.)
If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly.

41. INSPECT CHAIN TENSIONER SLIPPER
(a) Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.0394 in.)
If the depth is greater than the maximum, replace the chain tensioner slipper.

42. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Measure the worn depth of the No. 1 chain vibration damper.
Maximum depth: 1.0 mm (0.0394 in.)
If the depth is greater than the maximum, replace the No. 1 chain vibration damper.

43. INSPECT NO. 2 CHAIN VIBRATION DAMPER
(a) Measure the worn depth of the No. 2 chain vibration damper.
Maximum depth: 1.0 mm (0.0394 in.)
If the depth is greater than the maximum, replace the No. 2 chain vibration damper.

44. INSPECT EXHAUST MANIFOLD FOR FLATNESS
(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head.
Maximum warpage: 0.70 mm (0.0276 in.)
If warpage is greater than the maximum, replace the exhaust manifold.

HINT: Maximum warpage of each installation surface: 0.3 mm (0.0118 in.)

45. INSPECT INTAKE MANIFOLD FOR FLATNESS
(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head and intake air surge tank.
Maximum warpage:
for intake air surge tank side: 0.80 mm (0.0315 in.)
for cylinder head side: 0.20 mm (0.00787 in.)
If warpage is greater than the maximum, replace the intake manifold.