Part 2
OVERHAUL
30. INSTALL STRAIGHT PIN
a. Using a plastic-faced hammer, tap in the straight pins to the specified protrusion height.
Protrusion height:
A 5 mm (0.1969 inch)
B 7.5 mm (0.2953 inch)
C 9 mm (0.3543 inch) or more
D 8 mm (0.3150 inch)
31. INSTALL TIGHT PLUG
a. Apply adhesive around tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Using SST, tap in the tight plugs A until its surface is flush with the cylinder block.
c. Using SST, tap in the tight plugs B to the specified protrusion height.
Protrusion height:
B 1.5 - 2.5 mm (0.0591 - 0.0984 inch)
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100, 09951-00450)
32. INSTALL SUB-ASSY OIL NOZZLE NO.1
a. Using a bi-hexagon wrench (5), install the oil nozzle No.l.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
33. INSTALL PISTON PIN HOLE SNAP RING
a. 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.
34. INSTALL W/ PIN PISTON SUB-ASSY
a. Coat the piston pin with engine oil.
b. Align the front marks on the piston and connecting rod, and push in the piston with your thumb.
35. INSTALL PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
HINT: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.
36. INSTALL PISTON RING SET
HINT: In case of reusing the piston rings, install them to the matched pistons with the surfaces faced 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 the piston rings so that the ring ends are as shown.
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 and let not stick the oils and fats.
38. INSTALL CRANKSHAFT
a. Install the upper bearing with an oil groove on cylinder block.
NOTICE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
b. Install the lower bearing on the bearing cap sub assembly.
NOTICE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
c. Install the 2 thrust washers upper the No. 3 journal position of the cylinder block with the oil grooves facing outward.
d. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
e. Apply a light coat of engine oil on the bolt threads, the bolt seats, and the bearings of the bearing cap sub assembly.
f. Apply seal packing in the shape of bead (Diameter 2.5 - 3.5 mm (0.08 - 0.12 inch) consequently 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 after applying seal packing.
^ Do not put into engine oil within 2 hours after the installation.
g. Using socket wrench (12), tighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)
h. Using socket wrench (12), retighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
i. Mark the front of the bearing cap sub-assembly bolts with paint.
j. Retighten the bearing cap sub-assembly bolts by 45 twice, in the numerical order shown.
k. Check that the painted mark is now at a 90° angle to the front.
l. Tighten 10 other bolts for the bearing cap.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
m. apply adhesive to 2 or 3 threads, and install the 4 screw plugs.
Adhesive:
Part No. 08833-0070, THREE BOND 1324, or equivalent
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
39. INSTALL CONNECTING ROD SUB-ASSY
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.
d. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
NOTICE:
^ 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.
e. Check that the protrusion of the connecting rod cap is facing in the correct direction.
f. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
g. Using SST, tighten the bolts in several passes by the specified torque.
SST 09205-16010
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
h. Mark the front of the connecting cap bolts with paint.
i. Retighten the cap bolts by 90° as shown in the illustration. Check that the crankshaft turns smoothly.
40. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Apply two or three threads of adhesive to the drain union, and install it within 3 minutes.
Torque: 25 Nm (255 kgf-cm 18 ft. lbs.)
b. After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.
NOTICE:
^ Do not put into coolant in an hour after the installation.
^ Do not rotate the drain union more than 360° in (b), and never loosen it after setting the union correctly.