Main Bearings, Crankshaft and Cylinder Block
Removal
1. Remove engine assembly from vehicle.
2. Remove clutch and flywheel (M/T) or drive plate (A/T).
Special tool
(A): 09924-17810
3. Remove throttle body, intake manifold, exhaust manifold.
4. Remove oil pan.
5. Remove oil pump with oil pump strainer.
6. Remove cylinder head cover.
7. Remove timing chain cover.
8. Remove timing chain guide, chain tensioner, tensioner adjusters, 2nd timing chain and 1st timing chain.
9. Remove cylinder head assembly.
10. Remove pistons and connecting rods.
11. Remove crankshaft position sensor (1).
12. Remove water pump (1) and heater outlet pipe.
13. Remove engine front mounting bracket (2).
14. Loosen crankcase bolts, the following sequence in figure and remove them.
15. Remove crankshaft from cylinder block.
Installation
NOTE:
^ All parts to be installed must be perfectly clean.
^ Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores.
^ Journal bearings, crankcase (bearings caps), connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb combination and try to see that each part goes back to where it came from, when installing.
^ Clean mating surface of cylinder block and lower crankcase, remove oil, old sealant and dust from mating surface.
1. Fit main bearings (4) to cylinder block (1). One of two halves of main bearing, has oil groove (3). Install this half with oil groove to cylinder block, and another half without oil groove to cylinder block, and another half without oil groove to lower crankcase. Make sure that two halves are painted in the same color.
2. Install O-ring (2) to cylinder block.
3. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs.
4. Put crankshaft (1) with oil pump chain to cylinder block.
5. Apply sealant "A"to lower crankcase (1) mating surface area as shown in figure.
"A": Sealant 99000-31150
6. Install lower crankcase (1) to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase bolts, the following numerical order in figure. Tighten crankcase bolts to specified torque.
NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
Tightening torque
Main bearing cap bolt (a): 59 Nm (5.9 kg-m, 43.0 ft. lbs.)
Lower crankcase bolt (b): 27 Nm (2.7 kg-m, 19.5 ft. lbs.)
7. Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) by using special tools and plastic hammer.
Special tool
(A): 09911-97710
(B): 09911-97810
8. Install dowel pin.
9. Install crankshaft position sensor.
10. Install flywheel or drive plate. Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts applied with thread lock cement to specification.
"A": Thread lock 99000-32110
Special tool
(A): 09924-17810
Tightening torque
Flywheel or drive plate bolt (a): 70 Nm (7.0 kg-m, 51.0 ft. lbs.)
11. Install engine front mounting bracket (1). Tighten bracket bolts to specified torque.
Tightening torque
Engine front mounting bracket bolt (a): 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
12. Install water pump (2) and heater outlet pipe (3).
13. Install pistons and connecting rods.
14. Install oil pump.
15. In case of oil pump chain guide (1) is reinstalled or new oil pump chain is installed, if chain guide hole is oval type, adjust clearance between oil pump chain and oil pump chain guide as follows:
a. Install oil pump chain guide and nuts (2) temporarily.
b. To take up slack of oil pump chain, insert 0.5 mm (0.020 inch) thickness gauge (3) between chain guide and chain and pull chain guide in arrow direction with a force of 20 to 30 N (2 - 3 kg, 4.4 - 6.6 lb).
c. With pulling chain guide in Step b), tighten oil pump chain guide nuts and pull out thickness gauge.
16. Install cylinder head assembly to cylinder block.
17. Install timing chain sprockets, timing chains, timing chain tensioners, tensioner adjusters, timing chain guides, timing chain cover, crankshaft pulley, water pump pulley, etc.
18. Install oil pump, oil pump strainer and oil pan.
19. Install clutch to flywheel (for M/T vehicle).
20. Install engine assembly to vehicle.
Crankshaft Inspection
Crankshaft Runout
Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft.
Crankshaft runout
Limit: 0.06 mm (0.0023 inch)
Crankshaft Thrust Play
Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed. Tighten crankcase bolts to specified torque in such order as indicated in the figure.
Tightening torque
Main bearing cap bolt (a): 59 Nm (5.9 kg-m, 43.0 ft. lbs.)
Lower crankcase bolt (b): 27 Nm (2.7 kg-m, 19.5 ft. lbs.)
Use a dial gauge to read displacement in axial (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard thrust play.
Crankshaft thrust play
Standard: 0.10 - 0.35 mm (0.0039 - 0.0138 inch)
Limit: 0.42 mm (0.0149 inch)
Thickness of crankshaft thrust bearing
Standard: 2.500 mm (0.0984 inch)
Oversize (0.125 mm (0.0049 inch): 2.563 mm (0.1009 inch)
Out-Of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This difference, if any, is determined by taking micrometer readings. If any one of journals is badly damaged or if amount of uneven wear in the sense explained above exceeds its limit, regrind or replace crankshaft.
Out-of-round (A - B) and taper (a - b)
Limit: 0.01 mm (0.0004 inch)
Main Bearings Inspection
NOTE: Before inspect main bearings, note the following points.
^ Service main bearings are available in standard size and 0.25 mm (0.0098 inch) undersize, and standard size has 5 kinds of bearings differing in tolerance.
^ Upper half (1) of bearing has oil groove (2) as shown in the figure. Install this half with oil groove to cylinder block.
^ Lower half of bearing does not have oil groove.
Visual Inspection
Check bearings for pitting, scratches, wear or damage. If any malcondition is found, replace both upper and lower halves. Never replace either half without replacing the other half.
Main Bearing Clearance
Check clearance by using gaging plastic (1) according to the following procedure.
1. Remove lower crankcase.
2. Clean bearings and main journals.
3. Place a piece of gaging plastic to full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
4. Install lower crankcase to cylinder block. Tighten crankcase bolts, the following sequence in figure. Tighten crankcase bolts to specified torque.
Tightening torque
Main bearing cap bolt (a): 59 Nm (5.9 kg-m, 43.0 ft. lbs.)
Lower crankcase bolt (b): 27 Nm (2.7 kg-m, 19.5 ft. lbs.)
NOTE: Do not rotate crankshaft while gaging plastic is installed.
5. Remove lower crankcase and using scale (2) on gaging plastic (1) envelop, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use of 0.25 mm undersize bearing. After selecting new bearing, recheck clearance.
Main bearing clearance
Standard: 0.032 - 0.052 mm (0.0013 - 0.0020 inch)
Limit: 0.060 mm (0.0023 inch)
Selection of Main Bearings
Standard bearing
If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it.
1. First check journal diameter. As shown in figure, crank web No.2 (3) has stamped numbers. Three kinds of numbers ("1", "2" and "3") represent the following journal diameters. Stamped numbers on crank web No.2 represent journal diameters marked with an arrow in figure respectively. For example, stamped number "1" indicates that corresponding journal diameter is 57.994 - 58.000 mm.
Journal diameter
2. Next, check crankcase (bearing cap) bore diameter without bearing. On lower crankcase five alphabets are stamped as shown in figure. Three kinds of alphabets ("A", "B" and "C") represent the following cap bore diameters. Stamped alphabets on lower crankcase represent crankcase bore diameter marked with an arrow in figure respectively. For example, stamped alphabet "A" indicates that corresponding bearing cap bore diameter is 62.000 - 62.006 mm.
Bearing cap bore diameter (without bearing)
3. There are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicates the following thickness at the center of bearing.
Standard size main bearing thickness
4. From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal. For example, if number stamped on crank web No.2 is 1.and alphabet stamped on lower crankcase is "B", install a new standard bearing painted in "Black" to its journal.
New standard size bearing specification
5. Using gaging plastic (1), check bearing clearance with newly selected standard bearing. If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
6. When replacing crankshaft or cylinder block and lower crank case due to any reason, select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new lower crankcase.
Undersize bearing (0.25 mm)
^ 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in figure. Each color represents the following thickness at the center of bearing.
Undersize main bearing thickness
^ If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Finished journal diameter 57.732 - 57.750 mm (2.2729 - 2.2736 inch)
b. Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
c. Using journal diameter measured above and alphabets stamped on lower crankcase, select an undersize bearing.
Check bearing clearance with newly selected undersize bearing.
Undersize bearing specification
Crankshaft Position Sensor Plate Inspection
^ Check teeth of plate (2) for damage.
If any damage is found, replace crankshaft (1).
Oil Pump Sprocket and Oil Pump Chain Inspection
Oil Pump Sprocket
^ Check teeth of sprocket (2) for wear or damage.
If any damage or wear is found, replace crankshaft (1).
Oil Pump Chain
^ Check oil pump chain for wear or damage.
Rear Oil Seal and Flywheel Inspection
Rear Oil Seal
^ Carefully inspect oil seal for wear or damage. If lip portion is worn or damaged, replace oil seal.
Flywheel
^ If ring gear is damaged, cracked or worn, replace flywheel.
^ If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.
^ Check flywheel for face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel runout
Limit: 0.2 mm (0.0078 inch)
Cylinder Block Inspection
Distortion of Gasketed Surface
^ Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It.
Gasketed surface flatness of cylinder block
Limit: 0.06 mm (0.0024 inch)
Honing or Reboring Cylinders
1. When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2. Select oversized piston according to amount of cylinder wear.
Oversize piston diameter
STD: 83.970 - 83.990 mm (3.3059 - 3.3066 inch)
O/S 0.50: 84.470 - 84.490 mm (3.3256 - 3.3263 inch)
3. Using micrometer, measure piston diameter.
4. Calculate cylinder bore diameter to be rebored as follows.
D = A + B - C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
C: Allowance for honing = 0.02 mm (0.0008 inch)
5. Rebore and hone cylinder to calculated dimension.
NOTE: Before reboring, install lower crankcase and tighten to specification to avoid distortion of bearing bores.
6. Measure piston clearance after honing.
Check Valve
Check check valve for clogging and ball for being stuck.