Part 2
OVERHAUL (CONTINUED)22. INSPECT CONNECTING ROD BOLT
a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter: 8.7 to 8.8 mm (0.3425 to 0.3465 inch)
Minimum diameter: mm (inch)
If the diameter is less than minimum, replace the connecting rod bolt.
23. 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 maximum, replace the crankshaft.
b) Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.
Diameter: 47.988 to 48.000 mm (1.8893 to 1.8898 inch)
If the diameter is not as specified, check the crankshaft oil clearance.
c) Check each main journal for taper and distortion as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
If the taper and distortion are greater than maximum, replace the crankshaft.
d) Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration.
Diameter: 44.992 to 45.000 mm (1.7713 to 1.7717 inch)
If the diameter is not as specified, check the connecting rod oil clearance.
e) Check each crank pin for taper and distortion as shown.
Maximum taper and distortion: 0.02 mm (0.0008 inch)
If the taper and distortion are greater than maximum, replace the crankshaft.
24. INSPECT CRANKSHAFT BEARING CAP BOLT
a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 inch)
Minimum diameter: 7.3 mm (0.287 inch)
If the diameter is less than minimum, replace the crankshaft bearing cap bolt.
25. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE: Do not turn the crankshaft.
a) Clean each main journal and bearing.
b) Place the crankshaft on the cylinder block.
c) Lay a strip of plastigage across each journal.
d) Using SST, tighten the 10 bolts to the specified torque in several passes in the sequence shown.
SST 09011-38121
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)
e) Using SST, retighten the 10 bolts to the specified torque in several passes in the sequence shown.
SST 09011-38121
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
f) Mark the front of each bearing cap bolts with paint.
g) Retighten each bearing cap bolt by 45° twice, in the sequence order shown.
h) Check that the paint mark of each bolt is at a 90° angle to the front.
i) Remove the bearing cap.
j) Measure the Plastigage at its widest point.
Standard oil clearance: 0.016 to 0.032 mm (0.0006 to 0.0013 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
NOTICE: Completely remove the Plastigage.
^ If the oil clearance is greater than minimum, replace the crankshaft bearing.
^ If necessary, replace the crankshaft.
k) When using a standard bearing, replace it with one with the same number. If the number of the bearing cannot be determined, refer to the following table to select a bearing.
Standard bearings selection chart
HINT: Cylinder block "4", Crankshaft "3", Use bearing "3".
26. INSTALL STUD BOLT
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for stud bolt A
5.0 Nm (51 kgf-cm, 44 inch lbs.) for stud bolt B
5.0 Nm (51 kgf-cm, 44 inch lbs.) for stud bolt C
19 Nm (194 kgf-cm, 14 ft. lbs.) for stud bolt D
11 Nm (112 kgf-cm, 8 ft. lbs.) for stud bolt E
27. INSTALL RING PIN
a) Using a plastic-faced hammer, tap in new ring pins to the specified protrusion height.
Protrusion height
28. INSTALL STRAIGHT PIN
a) Using a plastic-faced hammer, tap in new straight pins to the specified protrusion height.
Protrusion height
29. INSTALL TIGHT PLUG
a) Apply adhesive around new tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b) Using SST, tap in new tight plugs A until their surfaces are flush with the cylinder block.
c) Using SST, tap in new tight plugs B to the specified protrusion height.
Protrusion height: 1.5 to 2.5 mm (0.059 to 0.098 inch) for tight plug B
SST 09950-60010 (09951-00250, 09951-00450), 09950-70010 (09951-07100)
30. INSTALL SUB-ASSEMBLY OIL NOZZLE NO. 1
a) Using a 5 mm socket hexagon wrench, install the 4 oil nozzles.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
31. INSTALL CRANKSHAFT BEARING
a) Install the upper bearing with an oil groove on cylinder block.
NOTICE: Do not apply engine oil to the bearing and its contact surface.
b) Install the lower bearing onto the bearing cap.
NOTICE: Do not apply engine oil to the bearing and its contact surface.
32. INSTALL CRANKSHAFT THRUST WASHER UPPER
a) Install the 2 thrust washers upper onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
33. INSTALL CRANKSHAFT
a) Apply engine oil to upper bearing, then install the crankshaft on the cylinder block.
b) Apply a light coat of engine oil to the bolt threads, bolt seats, and bearings of the bearing cap.
c) Install the crankshaft into the cylinder block.
d) Apply a continuous bead of seal packing as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the bearing cap sub-assembly within 3 minutes of applying seal packing.
^ Do not put in engine oil for at least 2 hours after installation.
e) Using SST, tighten the 10 bolts to the specified torque in several passes in the sequence shown.
SST 09011-38121
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)
f) Using SST, retighten the 10 bolts to the specified torque in several passes in the sequence shown.
SST 09011-38121
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
g) Mark the front of each bearing cap bolts with paint.
h) Retighten each bearing cap bolts by 45° twice, in the sequence order shown.
i) Check that the paint mark of each bolt is now at a 90° angle to the front.
j) Tighten the 10 other bolts for the bearing cap.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
k) Apply adhesive to 2 or 3 threads of the 4 screw plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324, or equivalent
l) Using a 14 mm straight hexagon wrench, remove the 4 screw plugs.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
34. INSTALL W/PIN PISTON SUB-ASSEMBLY
a) Using a small screwdriver, install a new snap ring onto one end of each piston pin hole.
HINT: Make sure that the end gap of the snap ring is aligned with the pin hole cutout portion of the piston.
b) Coat the piston pin with engine oil.
c) Align the front marks on the piston and connecting rod, then push in the piston with your thumb.
d) Using a small screwdriver, install a new snap ring onto the other end of each piston pin hole.
HINT: Make sure that the end gap of each snap ring is not aligned with the pin hole cutout portion of each piston.
35. INSTALL PISTON RING SET
HINT: If reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.
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 code mark facing upward.
Code mark: T
c) Position each piston ring so that ring ends is as shown.
36. INSTALL CONNECTING ROD BEARING
a) Align the connecting rod bearing claw with the oil groove of the connecting rod cap.
b) Install the connecting rod bearing onto the connecting rod cap.
NOTICE: Do not apply engine oil to the bearing and its contact surface.
c) Align the connecting rod bearing claw with the oil groove of the connecting rod.
d) Install the connecting rod bearing onto the connecting rod.
NOTICE: Do not apply engine oil to the bearing and its contact surface.
37. INSTALL CONNECTING ROD SUB-ASSEMBLY
a) Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
b) Check the position of the piston ring ends.
c) Using a piston ring compressor, correctly push the numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
d) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, then install the connecting rod.
NOTICE: Match the numbered connecting rod cap with the same numbered connecting rod.
e) Check that the protrusion of the connecting rod cap is facing in the correct direction.
f) Apply a light coat of engine oil to the threads and under the heads of each connecting rod cap bolt.
g) Using SST, tighten the bolts to the specified torque in several passes in the sequence shown.
SST 09205-1 6010
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
h) Mark the front of each connecting cap bolts with paint.
i) Retighten each cap bolts by 90° as shown in the illustration.
j) Check that the crankshaft turns smoothly.
38. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a) Apply adhesive to 2 or 3 threads of the cylinder block water drain cock, then install it within 3 minutes of applying as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b) After tightening the drain cock to the specified torque, rotate the drain union clockwise until its drain port faces downward.
NOTICE:
^ Do not put in coolant for at least an hour after installation.
^ Do not turn the drain union more than 360° in (b), and never loosen it after setting the union correctly.