Remove the connecting rod caps/bearing. Keep all connecting rod caps/bearing halves in order.
8.
Cylinder Lower Block - Remove
1.
Remove the 8 mm bolts.
2.
Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
3.
Remove the lower block and the bearings. Keep all the bearings in order.
9.
Crankshaft - Remove
Lift the crankshaft out of the engine block.
10.
CKP Pulse Plate - Remove
Remove the CKP pulse plate.
1.
Crankshaft - Inspect
1.
Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
2.
Check the keyway slot and the threaded holes for damage.
3.
Measure the out-of-round at the middle of each rod and the main journal in two places. The difference between measurements on each journal must not be more than the service limit.
Journal Out-of-Round
Standard (New):
0.004 mm (0.00016 in) max.
Service Limit:
0.010 mm (0.00039 in)
4.
Measure the taper at the edges of each rod and the main journal. The difference between measurements on each journal must not be more than the service limit.
Journal Taper
Standard (New):
0.005 mm (0.00020 in) max.
Service Limit:
0.010 mm (0.00039 in)
5.
Place the V-blocks on a flat surface.
6.
Check the total runout with the crankshaft supported on V-blocks.
7.
Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit.
Crankshaft Total Runout
Standard (New):
0.03 mm (0.0012 in) max.
1.
Crankshaft End Bushing - Install (M/T)
Install the crankshaft end bushing when replacing the crankshaft. Using the driver handle, 15 x 135L and the bearing driver attachment, 24 x 26 mm, drive in the crankshaft end bushing until the driver handle and the bearing driver attachment bottom against the crankshaft.
Install the bearing halves in the engine block and the connecting rods.
2.
Apply a coat of new engine oil to the main bearings and the connecting rod bearings.
3.
Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, then lower the crankshaft into the engine block.
NOTE: Be careful not to damage the journals and the CKP pulse plate.
4.
Apply new engine oil to the thrust washer surfaces. Install the thrust washers in the No. 4 journal of the engine block.
5.
Cylinder Lower Block - Install
1.
Remove all of the old liquid gasket from the lower block mating surfaces, the bolts, and the bolt holes.
2.
Clean and dry the lower block mating surfaces.
3.
Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the engine block mating surface of the lower block and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
4.
Put the lower block on the engine block.
5.
Apply new engine oil to the threads of the bearing cap bolts. Torque the bearing cap bolts in sequence, to 35 N·m (3.6 kgf·m, 26 lbf·ft).
6.
Tighten the bearing cap bolts an additional 41 °.
7.
Torque the 8 mm bolts in sequence to 24 N·m (2.2 kgf·m, 16 lbf·ft).
NOTE:
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the lower block.
Measure the diameter of each connecting rod bolt at point A and point B.
2.
Calculate the difference in diameter between point A and point B.
Point A?Point B = Difference in Diameter
Difference in Diameter
Specification:
0?0.1 mm (0?0.004 in)
3.
If the difference in diameter is out of specification, replace the connecting rod bolt.
8.
Connecting Rod Cap and Bearing Half - Install
1.
Apply new engine oil to the threads of the connecting rod bolts.
2.
Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the bearing cap.
3.
Install the bearing caps and the bolts finger-tight.
4.
Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and the bearing cap.
5.
Install the bearing caps and the bolts finger-tight.
6.
Tighten the connecting rod bolts to 5 N·m (0.5 kgf·m, 4 lbf·ft).
7.
Torque the connecting rod bolts to 40.7 N·m (4.15 kgf·m, 30.0 lbf·ft).
8.
Tighten the connecting rod bolts an additional 120 °.
NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen it back to the specified angle.
