Assembly
NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.
CRANKSHAFT BEARING SELECTION
If using a standard bearing, replace it with or having 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 below for the appropriate bearing number.
There are five sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked "3" "4" "5" "6" and "7 . For others position bearings, use bearings marked "1", "2", "3", "4" and "5".
Reference marks for cylinder block main journal bore diameter (A):
Mark "00" 72.000 mm (2.8346 in).
Mark "01" 72.001 mm (2.8347 in).
Mark "02" 72.002 mm (2.8347 in).
Mark "03" 72.003 mm (2.8348 in).
Mark "04" 72.004 mm (2.8348 in).
Mark "05" 72.005 mm (2.8348 in).
Mark "06" 72.006 mm (2.8349 in).
Mark "07" 72.007 mm t2.8349 in).
Mark "08" 72.008 mm (2.8350 in).
Mark "09" 72.009 mm (2.8350 in).
Mark "10" 72.010 mm (2.8350 in).
Mark "11" 72.011 mm (2.8351 in).
Mark "12" 72.012 mm (2.8351 in).
Mark "13" 72.013 mm (2.8352 in).
Mark "14" 72.014 mm (2.8352 in).
Mark "15" 72.015 mm (2.8352 in).
Mark "16" 72.016 mm (2.8353 in.}
Reference marks for crankshaft main journal diameter (B):
Mark "00" 67.000 mm (2.6378 in).
Mark "01" 66.999 mm (2.6378 in).
Mark "02" 66.998 mm (2.6377 in).
Mark "03" 66.997 mm (2.6377 in).
Mark "04" 66.996 mm (2.6376 in).
Mark "05" 66.995 mm (2.6376 in).
Mark "06" 66.994 mm (2.6376 in).
Mark "07" 66.993 mm (2.6375 in).
Mark "08" 66.992 mm (2.6375 in).
Mark "09" 66.991 mm (2.6374 in).
Mark "10" 66.990 mm (2.6374 in).
Mark "11" 66.989 mm (2.6374 in).
Mark "12" 66.988 mm (2.6979 in).
Reference marks for standard bearing center wall thickness:
Bearings No.1 and No.5
Mark "3" 2.492-2.495 mm (0.0981-0.0982 in).
Mark "4" 2.495-2.498 mm (0.0982-0.0983 in).
Mark "5" 2.498-2.501 mm (0.0983-0.0985 in).
Mark "6" 2.501-2.504 mm (0.0985-0.0986 in).
Mark "7" 2.504-2.507 mm (0.0986-0.0987 in).
All other main bearings
Mark "1" 2.486-2.489 mm (0.0979-0.0980 in).
Mark "2" 2.489-2.492 mm (0.0980-0.0981 in).
Mark "3" 2.492-2.495 mm (0.0981-0.0982 in).
Mark "4" 2.495-2.498 mm (0.0982-0.0983 in).
Mark "5" 2.498-2.501 mm (0.0983-0.0985 in).
ROD BEARING SELECTION
If using a standard bearing, replace it with one having the same number.
If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the total.
There are six sizes of standard bearings. marked "6" and "7"
Reference marks for connecting rod big end inside diameter.
Mark "1" 55.000-55.006 mm (2.1654-2.1656 in).
Mark "2" 55.006-55.012 mm (2.1656-2.1658 in).
Mark "3" 55.012-55.018 mm (2.1658-2.1661 in).
Mark "4" 55.018-55.024 mm (2.1661-2.1663 in).
Reference marks for crankshaft crank pin diameter:
Mark "1" 51.994-52.000 mm (2.0470-2.0472 in).
Mark "2" 51.988-51.994 mm (2.0468-2.0470 in).
Mark "3" 51.982-51.988 mm (2.0465-2.0468 in).
Reference marks for standard sized bearing center wall thickness:
Mark "2" 1.484-1.487 mm 10.0584-0.0585 in).
Mark "3" 1.487-1.490 mm (0.0585-0.0587 in).
Mark "4" 1.490-1.493 mm (0.0587-0.0588 in).
Mark "5" 1.493-1.496 mm (0.0588-0.0589 in).
Mark "6" 1.496-1.499 mm (0.0589-0.0590 in).
Mark "7" 1.499-1.502 mm (0.0590-0.0591 in).
ASSEMBLY
1. Install main bearings as follows:
NOTE:
- Main bearings come in widths of 19.5 mm (0.768 in) and 22.5 mm (0.886 in).
- Install the 22.5 mm (0.886 in) bearings in the No.1 and No.5 cylinder block journal positions with the main bearing cap.
- Install the 19.5 mm (0.763 in) bearings in the other positions.
- Upper bearings have an oil groove and oil holes; lower bearings do not.
(a) Align the bearing claw with the claw groove of the cylinder block, and push in the five upper bearings.
(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the five lower bearings.
NOTE: A number is marked on each main bearing cap to indicate the installation position.
2. Install the two thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.
3. Place crankshaft on cylinder block.
4. Install main bearing caps and lower thrust washers on the cylinder block.
(a) Install the two thrust washers on the No.3 bearing cap with the grooves facing outward.
(b) Install the five main bearing caps in their proper locations.
NOTE:
- Place the bearing caps level and let them return to their original position by their own weight.
- Do not install the main bearing cap by tapping it.
- The main bearing cap nuts are tightened in two progressive steps.
- If any one of the main bearing cap stud nuts is broken or deformed, replace it.
(c) Apply a light coat of engine oil on the threads and under the main bearing cap nuts.
(d) Using sequence shown, install and uniformly tighten the 20 main bearing cap nuts in several passes to 27 Nm (275 kg.cm, 20 ft.lb).
NOTE: If any one of the main bearing cap nuts does not meet the torque specification, replace the main bearing cap stud bolt.
(e) Mark the front of the main bearing cap nut with paint.
(f) Tighten the main bearing cap nuts by an additional 90° in the numerical order shown.
(g) Check that the painted mark is now at a 90° angle to the front.
(h) Install a new seal washer to the main bearing cap bolts.
(i) Install and uniformly tighten the 10 main bearing cap bolts to 49 Nm (500 kg.cm, 36 ft.lb).
(j) Check that the crankshaft turns smoothly.
5. Check crankshaft thrust clearance as described under Testing and Inspection.
6. Using a suitable piston ring compressor, push the correctly numbered piston and connecting rod assembly into each cylinder with the front mark of the piston facing forward.
NOTE: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".
7. Install connecting rod caps as follows:
(a) Match the numbered connecting rod cap with the connecting rod.
(b) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
(c) Check that the outside mark of the connecting rod cap is facing in correct direction.
NOTE:
- The connecting rod cap bolts are tightened in two progressive steps.
- If any one of the connecting rod cap bolts is broken or deformed, replace it.
(d) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(e) Install and alternately tighten the two connecting rod cap bolts in several passes to 25 Nm (250 kg.cm, 18 ft.lb).
NOTE: If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
(f) Mark the front of the connecting cap bolt with paint.
(g) Tighten the cap bolts an additional 90° as shown.
(h) Check that the painted mark is now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
8. Check connecting rod thrust clearance as described under Connecting Rod, Engine.
9. Install rear oil seal retainer as follows:
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
- Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
(b) Using a nozzle that has been cut to a 2-3 mm (0.08-0.1 two in) opening, apply seal packing part No. 08826-00080, or equivalent, to the oil seal retainer as shown in the illustration.
NOTE:
- Parts must be assembled within five minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
(c) Install a new O-ring to the cylinder block.
(d) Install the oil seal retainer with the seven bolts, then tighten to 8.0 Nm (80 kg.cm, 71 inch lbs.).