Engine Mechanical Cylinder Block Assembly: Overhaul

1. Remove the cylinder block water drain cock from the cylinder block.

Fig 1: Removing Cylinder Block Water Drain Cock

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1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

   Standard thrust clearance: 0.160 - 0.342 mm (0.063 - 0.0135 in.) 

   Maximum thrust clearance: 0.342 mm (0.0135 in.) 

If the thrust clearance is greater than maximum, replace the connecting rod.

If necessary, replace the crankshaft.

Fig 2: Measuring Thrust Clearance While Moving Connecting Rod

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1. Using marking paint, write the matched cylinder number on each connecting rod and cap.

   HINT:

   The match marks on the connecting rods and caps are for ensuring correct reassembly.

   Fig 3: Locating Match Marks On Connecting Rods And Caps

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2. Using SST, remove the 2 bolts and connecting rod cap.

   SST 09205-16010

3. Clean the crank pin and bearing.
4. Check the crank pin and bearing for pitting and scratches.
   Fig 4: Removing Connecting Rod Cap

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5. Lay a strip of Plastigage across the crank pin.
   Fig 5: Laying A Strip Of Plastigage Across The Crank Pin

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6. Check that the front mark of the connecting rod cap is facing in the correct direction.
7. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
   Fig 6: Checking Front Mark Of Connecting Rod

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8. Using SST, tighten the bolts in several passes by the specified torque.

   SST 09205-16010

   Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

   Fig 7: Tightening Connecting Rod Cap Bolts

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9. Mark the front of the connecting cap bolts with paint.
10. Retighten the cap bolts by 90° as shown in the illustration.
11. Check that the crankshaft turns smoothly.
    Fig 8: Locating Mark Of Connecting Cap Bolts

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12. Remove the 2 bolts and connecting rod cap.
    Fig 9: Removing Connecting Rod Cap

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13. Measure the Plastigage at its widest point.
    Fig 10: Measuring Plastigage At Its Widest Point

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    Standard oil clearance: 

    0.028 - 0.060 mm (0.0011 - 0.0024 in.) 

    Maximum oil clearance: 0.080 mm (0.0032 in.) 

If the oil clearance is greater than maximum, replace the connecting rod bearing.

If necessary, grind or replace the crankshaft.

HINT:

If replacing a bearing, select a new one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

Fig 11: Locating Connecting Rod Cap Mark

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Fig 12: Bearings Mark Standard Table

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1. Using a ride reamer, remove all the carbon from the top of the cylinder.
   Fig 13: Removing Carbon From Top Of Cylinder

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2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:

• Keep the bearing, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.

Fig 14: View Of Connecting Rod Assembly

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1. Remove the connecting rod bearing from the connecting rod cap.
   Fig 15: Identifying Connecting Rod Cap

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2. Remove the connecting rod bearing from the connecting rod.
   Fig 16: Identifying Connecting Rod

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1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.

Fig 17: Removing Piston Ring

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1. Using a small screwdriver, pry out the 2 snap rings.
   Fig 18: Removing Snap Rings

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2. Heat the piston to 80 - 90°C (176 - 194°F).
   Fig 19: Applying Heat To Pistons

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3. Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

HINT:

• The piston and pin are a matched set.
• Arrange the piston, pins, ring, connecting rod and bearings in the correct order.

Fig 20: Removing Piston Pin And Connecting Rod

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1. Remove the 10 bolts.
   Fig 21: Removing 10 Bolts

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2. Uniformly loosen the 10 bearing cap bolts, in several passes, in the sequence shown in the illustration.

   SST 09011-38121

   Fig 22: Loosening Bearing Cap Bolts In Sequence

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3. Using a screwdriver, remove the bearing cap by prying the indicated portions between the cylinder block and bearing cap.
   NOTE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap.
   Fig 23: Locating Areas To Pry Between Cylinder Block And Bearing Cap

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4. Remove the crankshaft from the cylinder block.
   Fig 24: Removing Crankshaft From Cylinder Block

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1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

   Standard thrust clearance: 

   0.04 - 0.24 mm (0.0016 - 0.0095 in.) 

   Maximum thrust clearance: 0.30 mm (0.0118 in.) 

If the thrust clearance is greater than maximum, measure the thrust washer thickness.

If the thickness is not specified, replace the thrust washer.

HINT:

Thrust washer thickness: 2.430 - 2.480 mm (0.0957 - 0.0976 in.).

Fig 25: Measuring Thrust Clearance

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1. Remove the 2 crankshaft thrust washers from the cylinder block.

Fig 26: Removing Crankshaft Thrust Washers

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1. Remove the 5 crankshaft bearings from the cylinder block.
   NOTE: Arrange the main bearings and thrust washers in the correct order.
   Fig 27: Removing Crankshaft Bearings From Cylinder Block

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2. Remove the 5 crankshaft bearings from the bearing cap.
   NOTE: Arrange the main bearings and thrust washers in the correct order.
   Fig 28: Removing Crankshaft Bearings From Bearing Cap

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1. Using torx socket wrench E5 and E7, remove the 9 stud bolts.

Fig 29: Removing Stud Bolt

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1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

   Maximum warpage: 0.05 mm (0.0020 in.) 

If the warpage is greater than maximum, replace the cylinder block.

Fig 30: Measuring Surface Contacting Cylinder Head Gasket For Warpage

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1. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

   Standard diameter: 

   79.000 - 79.013 mm (3.1102 - 3.1108 in.) 

   Maximum diameter: 

   79.013 mm (3.1108 in.) 

If the diameter is greater than maximum, replace the cylinder block.

Fig 31: Measuring Cylinder Bore

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1. Using a micrometer, measure the piston diameter at a right angle to the piston pin hole, and at the piston of 25.6 mm (1.008 in.) from the piston head.

   Piston diameter: 

   78.872 - 78.972 mm (3.1052 - 3.1091 in.) 

Fig 32: Measuring Piston Diameter

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1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

   Standard oil clearance: 0.065 - 0.088 mm (0.0026 - 0.0035 in.) 

   Maximum oil clearance: 0.088 mm (0.0035 in.) 

If the oil clearance is greater than maximum, replace all the pistons. If necessary, replace the cylinder block.

1. Using a caliper gauge, measure the piston pin bore diameter.

   Piston pin bore diameter: 

   20.006 - 20.015 mm (0.78764 - 0.78799 in.) 

   PISTON PIN OIL CLEARANCE CHECK
   
   

   Mark	mm (in.)
   A	20.006 - 20.009 (0.78764 - 0.78776)
   B	20.010 - 20.012 (0.78780 - 0.78787)
   C	20.013 - 20.015 (0.78791 - 0.78799)

   Fig 33: Measuring Piston Pin Bore Diameter

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2. Using a micrometer, measure the piston pin outer diameter.

   Piston pin outer diameter: 

   20.004 - 20.013 mm (0.78756 - 0.78791 in.) 

   PISTON PIN BORE DIAMETER CHECK
   
   

   Mark	mm (in.)
   A	20.004 - 20.007 (0.78756 - 0.78768)
   B	20.008 - 20.010 (0.78772 - 0.78780)
   C	20.011 - 20.013 (0.78783 - 0.78791)

   Fig 34: Measuring Piston Pin Outer Diameter

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3. Using a caliper gauge, measure the connecting rod small end bore diameter.

   Connecting rod small end bore diameter: 

   20.012 - 20.021 mm (0.78787 - 0.78823 in.) 

   CONNECTING ROD SMALL END BORE DIAMETER
   
   

   Mark	mm (in.)
   A	20.012 - 20.015 (0.78787 - 0.78799)
   B	20.016 - 20.018 (0.78803 - 0.78811)
   C	20.019 - 20.021 (0.78815 - 0.78823)

   Fig 35: Measuring Connecting Rod Small End Bore Diameter

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   Fig 36: Locating Front Mark

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4. Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.

   Standard oil clearance: 

   0.002 - 0.011 mm (0.0001 - 0.0004 in.) 

   Maximum oil clearance: 0.011 mm (0.0004 in.) 

   If the oil clearance is greater than maximum, replace the connecting rod.

   If necessary, replace the w/pin piston.

5. Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.

   Standard oil clearance: 

   -0.001 - 0.017 mm (-0.0004 - 0.0007 in.) 

   Maximum oil clearance: 0.017 mm (0.0007 in.) 

   If the oil clearance is greater than maximum, replace the connecting rod.

   If necessary, replace the connecting rod and w/pin piston.

1. Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.

   Ring groove clearance: 

   No. 1 0.020 - 0.070 mm (0.0008 - 0.0028 in.) 

   No. 2 0.030 - 0.070 mm (0.0012 - 0.0028 in.) 

   Oil 0.03 - 0.11 mm (0.0012 - 0.0043 in.) 

Fig 37: Measuring Clearance Between Piston Ring And Wall Of Ring Groove

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If the groove clearance is not as specified, replace the piston ring.

1. Using a piston, push the piston ring a little beyond the bottom of the ring travel, that means 110 mm (4.33 in.) from the top of the cylinder block.
   Fig 38: Inserting Piston Ring In Cylinder Block

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   Fig 39: Measuring Ring End Gap

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2. Using a feeler gauge, measure the end gap.

   Standard end gap: 

   No. 1 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 

   No. 2 0.35 - 0.50 mm (0.0138 - 0.0197 in.) 

   Oil 0.15 - 0.40 (0.0059 - 0.158 in.) 

   Maximum end gap: 

   No. 1 1.05 mm (0.0413 in.) 

   No. 2 1.20 mm (0.0472 in.) 

   If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with anew piston ring, replace the cylinder block.

1. Using a connecting 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 in.) per 100 mm (3.94 in.) 

      If out-of alignment is greater than maximum, replace the connecting rod assembly.

      Fig 40: Checking Connecting Rod Alignment

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   2. Check for twist.

      Maximum twist: 

      0.05mm (0.0020 in.) per 100 mm (3.94 in.) 

      If twist is greater than maximum, replace the connecting rod assembly.

      Fig 41: Checking Twist

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1. Using a vernier caliper, measure the tension portion diameter of the bolts.

   Standard diameter: 

   6.6 - 6.7 mm (0.260 - 0.264 in.) 

   Maximum diameter: 6.4 mm (0.252 in.) 

If the diameter is less than maximum, replace the connecting rod bolt.

Fig 42: Measuring Tension Portion Diameter Of Bolts

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1. Using a dial indicator and V-blocks, measure the circle runout, as shown in the illustration.

   Maximum circle runout: 0.03 mm (0.0012 in.) 

   If the circle runout is greater than maximum, replace the crankshaft.

   Fig 43: Measuring Circle Runout

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2. Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.

   Diameter: 47.988 - 48.000 mm (1.8893 - 1.8898 in.) 

   If the diameter is not as specified, check the crankshaft oil clearance.

3. Check each main journal for taper and out-of-round as shown.

   Maximum taper and out-of-round: 0.020 mm (0.0008 in.) 

   If the taper and out-of-round is greater than maximum, replace the crankshaft.

   Fig 44: Measuring Diameter Of Main Journal

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4. Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration.

   Diameter: 43.992 - 44.000 mm (1.7320 - 1.7323 in.) 

   If the diameter is not as specified, check the connecting rod oil clearance.

5. Check each crank pin for taper and out-of-round as shown.

   Maximum taper and out-of-round: 0.020 mm (0.0008 in.) 

   If the taper and out-of-round is greater than maximum, replace the crankshaft.

Fig 45: Measuring Crankpin Diameter

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1. Using vernier caliper, measure the tension portion diameter of the bolts.

   Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 in.) 

   Minimum diameter: 7.3 mm (0.287 in.) 

If the diameter is greater than minimum, replace the crankshaft bearing cap set bolt.

Fig 46: Measuring Tension Portion Diameter Of Bolts

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1. Clean each main journal and bearing.
2. Place the crankshaft on the cylinder block.
3. Lay a strip of Plastigage across each journal.
   Fig 47: Inspecting Crankshaft Oil Clearance

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4. Using SST, tighten the bolts in several passes, in the sequence shown, by the specified torque.

   SST 09011-38121

   Torque: 44 N.m (449 kgf.cm, 33 ft.lbf) 

   Fig 48: Tightening Bolt in Sequence

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5. Mark the front of the bearing cap bolts with paint.
6. Retighten the bearing cap bolts by 90° as shown in the illustration.
7. Check that the painted mark is now at a 90° angle to the front.
   Fig 49: Locating Bearing Cap Bolts Mark

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8. Tighten 10 other bolts for the bearing cap.

   Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

9. Remove the 10 Bolts.
   Fig 50: Tightening Bearing Cap Bolts

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10. Uniformly loosen the 10 bearing cap bolts, in several passes, in the sequence shown in the illustration.

    SST 09011-38121

    Fig 51: Loosening Bearing Cap Bolts

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11. Measure the plastigage at its widest point.
    Fig 52: Measuring Plastigage At Its Widest Point

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    Standard oil Clearance: 0.015 - 0.032 mm (0.0006 - 0.0013 in.) 

    Minimum oil clearance: 0.05 mm (0.0020 in.) 

If the oil clearance is greater than minimum, replace the crankshaft bearing.

If necessary, replace the crankshaft.

HINT:

If replacing a bearing, select a new one having the same number. If the number of the bearing cannot be determined, calculate the correct use bearing number by adding together the numbers imprinted on the cylinder block and crankshaft, then select a new bearing having the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

Fig 53: Standard Bearing Identification Chart

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EXAMPLE:

Cylinder block "3" (A) + Crankshaft "4" (B) = Total number 7 (Use bearing "3")

Fig 54: Standard Bearing Avalability Chart

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Fig 55: Identifying Cylinder Block And Crankshaft Imprinted Markings

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1. Using a plastic hammer, install the 9 straight pins to the cylinder block.

   Standard protrusion: 

   Straight pin A 5 mm (0.200 in.) 

   Straight pin B 7.5 mm (0.295 in.) 

   Straight pin C 12 mm (0.472 in.) 

   Straight pin D 8 mm (0.315 in.) 

Fig 56: Locating Straight Pin

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1. Using a plastic hammer, install the 5 ring pins to the cylinder block.

   Standard protrusion: 

   Ring pin A 6 mm (0.236 in.) 

   Ring pin B 7 mm (0.276 in.) 

   Ring pin C 10 mm (0.394 in.) 

Fig 57: Installing Ring Pin

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1. Using torx socket wrench E5 and E7, install the 9 stud bolt to the cylinder block.

   Torque: 

   Stud bolt A, C, D and E 5.0 N.m (51 kgf.cm, 44 in..lbf) 

   Stud bolt B 11 N.m (112 kgf.cm, 8 ft.lbf) 

Fig 58: Installing Stud Bolt

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1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.

   HINT:

   Be sure that end gap of the snap ring is aligned with the pin hole cutout portion of the piston.

   Fig 59: Installing Snap Ring

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2. Heat the piston to 80 - 90°C (176-194°F).
   Fig 60: Applying Heat To Piston

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3. Align the front marks on the piston with connecting rod, and push in the piston with your thumb.
   Fig 61: Aligning Front Marks On Piston With Connecting Rod

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4. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.

   HINT:

   Be sure that end gap of the snap ring is aligned with the pin hole cutout portion of the piston.

   Fig 62: Installing Snap Ring

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HINT:

In case of reusing the piston rings, install them to the matched pistons with the surfaces faced correctly.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

   Code mark (No.2 only): 2R 

   Fig 63: Installing Piston Ring Set

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3. Position the piston rings so that the ring ends are as shown.
   Fig 64: Positioning Piston Rings

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1. Install the upper bearing with an oil groove on cylinder block.
   NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
   Fig 65: Installing Upper Bearing With An Oil Groove On Cylinder Block

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2. Install the lower bearing on the bearing cap sub-assy.
   NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
   Fig 66: Installing Lower Bearing On Bearing Cap Sub-Assy

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1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 67: Installing Crankshaft Thrust Washer

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1. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
2. Apply a light coat of engine oil on the bolt threads, the bolt seats, and the bearings of the bearing cap sub-assy.
3. Install the crankshaft to the cylinder block.
   Fig 68: Installing Crankshaft On Cylinder Block

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4. Apply seal packing in the shape of bead (Diameter 2.5 - 3.5 mm (0.098 - 0.139 in.) consequently as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the bearing cap sub-assembly within 3 minutes after applying seal packing.
   • Do not put into engine oil within 2 hours after the installation.
   Fig 69: Applying Seal Packing In Shape Of Bead

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5. Using SST, tighten the bolts in several passes, in the sequence shown, by the specified torque.

   SST 09011-38121

   Torque: 44 N.m (449 kgf.cm, 33 ft.lbf) 

   Fig 70: Tightening Bolts In Sequence

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6. Mark the front of the bearing cap sub-assy bolts with paint.
7. Retighten the bearing cap sub-assy bolts by 90° as shown in the illustration.
8. Check that the painted mark is now at a 90° angle to the front.
   Fig 71: Locating Bearing Cap Sub-Assy Bolts Mark

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9. Tighten 10 other bolts for the bearing cap.

   Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

   Fig 72: Tightening Bearing Cap Bolts In Sequence

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1. Align the connecting rod bearing claw with the oil groove of the connecting rod cap.
2. Install the connecting rod bearing in the connecting rod cap.
   NOTE: Clean the backside of the bearing and bearing surface of the connecting rod cap and let not stick the oils and fats.
   Fig 73: Aligning Connecting Rod Bearing Claw With Oil Groove

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3. Align the connecting rod bearing claw with the oil groove of the connecting rod.
4. Install the connecting rod bearing in the connecting rod.
   NOTE: Clean the backside of the bearing and bearing surface of the connecting rod and let not stick the oils and fats.
   Fig 74: Aligning Connecting Rod Bearing Claw With The Oil Groove

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1. Position the piston rings so that the ring ends are as shown.
2. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
3. Check the position of the piston ring ends.
   Fig 75: Locating Front Mark

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4. 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.
   Fig 76: Installing Piston And Connecting Rod Assemblies Into Each Cylinder

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5. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
   NOTE:

   • Clean the backside and the surface of the connecting rod cap bearing and let not stick the oils and fats.
   • Match the numbered connecting rod cap with the same numbered connecting rod.
6. Check that the protrusion of the connecting rod cap is facing in the correct direction.
7. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
   Fig 77: Locating Front Mark

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8. Using SST, tighten the bolts in several passes by the specified torque.

   SST 09205-16010

   Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

   Fig 78: Tightening Bolt In Sequence

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9. Mark the front of the connecting cap bolts with paint.
10. Retighten the cap bolts by 90° as shown in the illustration.
11. Check that the crankshaft turns smoothly.
    Fig 79: Locating Connecting Cap Bolt Mark

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1. Apply 2 or 3 threads of adhesive to the cylinder block water drain cock, and install it within 3 minutes.

   Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

   Adhesive: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. After applying the specified torque, rotate the cylinder block water drain cock clockwise until its drain port faces downward.

Fig 80: Installing Cylinder Block Water Drain Cock

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