Main bearing HONDA CR-V 1997 RD1-RD3 / 1.G Workshop Manual

Engine Block - Section 7
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o*1: '97,'98 models 15 mm (0.6 in)'99,'00 models 20 mm (0.8 ini
Unit of length: mm (in)
MEASUREMENTSTANDARD (NEWISERVICE LIMIT
Cylinder blockWarpage of deck surfaceBore diameterBore taper
0.07 (0.003) max.84.00 - 84.02 (3.307 3.308)0.10 (0.004)
84.07 (3.310)
0.05 (0.002)
PistonSkirt O.D.*1trom bottom of skartClearance in cylinderGroove width {For ringi TopSecondoil
83.98 - 83.99 (3.306 - 3.307)0.01 - 0.04 (0.0004 - 0.001611.240 - 1.250 {0.0488 - 0.0492)1.220 1.230 {0.0480 - 0.0484)2.805 2.825 10.1104 - 0.1112)
83.97 (3.306)
0.05 {0.002)1.26 (0.0s0)
1.25 (0.049)
2.44lo.112l
Piston ringRing-to'groove clearance ToPSecondRing end gap ToPSecondoil
0.055 - 0.080 (0.0022 0.0031)0.035 0.060 (0.0014 - 0.0024)0.20 0.30 (0.008 - 0.012)0.40 - 0.55 (0.016 0.022)0.20 - 0.50 (0.008 - 0.020)
0.13 (0.005)
0.13 (0.005)
0.60 (0.024)
0.70 (0.028)
0.70 (0.028)
Piston Pino.D.Pin-to-piston clearance
20.996 - 21.000 (0.8266 - 0.8268i0.010 - 0.017 (0.0004 - 0.0007)
Connecting rodPin-to-rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
0.015 - 0.032 (0.0006 - 0.0013)20.968 -20.981 10.8255 -0.8260)
48.0 (1.89)
0.15 - 0.30 {0.006 - 0.012ioro to.oroi
CrankshaftMain journaldiameter
No. 1,2,4 and 5 iournalsNo. 3 journal
Rod iournal diameterTaperOut ol roundEnd play
Bunout
54.976 - 55.000 (2.'l644 - 2.1654)54.970 54.994 (2.1642 - 2.1651)44.976 - 45.000 /.1.1707 - 1.711110.005 (0.0002)max.
0.005 (0.0002) max.0.10 - 0.35 (0.004 - 0.0 r 4)0.03 (0.001)max.
0.010 (0.00041
0.010 (0.0004)
0.45 (0.0r8)
0.04 (0.002)
BearingMain bearing-to-iournal oil clearanceNo. 1, 2, 4 and 5 iournalsNo. 3 journal
Rod bearing-to-,ournal oil clearance
0.024 - 0.042 10.0009 0.0017)0.030 - 0.048 (0.0012 - 0.0019)0.020 - 0.038 (0.0008 0.0015)
0.06 (0.002)
0.06 (0.002)
0.05 (0.002)
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2-3
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Unit of length: mm lin)ClutchSection 12
Manual TransmissionSection 13
MEASUREMENTSTANDARD INEWISERVICE LIMIT
Clutch pedalPedal height to floorStrokeFree playPedal play
Disengagement height to floor
183 (7.20)
135- 14515.31 - 5.71)7 - 2210.24 - 0.41J1-9 (0.04-0.35)
7212.83) min.
Clutch surface runout0.05 (0.002) max.0.r5 (0.006)
Clutch discRivet head depthThickness1.2 - 1.710.05- 0.07)8.4 9.1 (0.33,0.36)0.2 (0.01)
6.0 i0.24)
Pressure plateWarpageDiaphragm spring finger alignment0.03 (0.001)max.
0.6 (0.02) max.0.15 (0.006)
0.8 (0.03)
MEASUREM€NTSTANDARD INEW} I SERVICE I-IMIT
TransmissionfluidCapacity f (US qt, lmp qti1.7 11.8, 1.4)for oilchange2.1 (2.2, 1.8){or overhaul
MainshaftEnd play
Diameter of ball bearing contact area (clutch side)Diameter of needle bearing contact areaDiameter of ball bearing contact area(transmission housing side)Runout
0.'11 - 0.18 (0.004 - 0.007)27.977 - 27.990 (1.1015 - 1.1020)37.984 - 38.000 (1.4954- 1.4961)
27.987 - 28.000 (1.1018 - 1.1024)0.02 (0.0011max.
Adjust27.94 (1.100)
37.93 (1.493)
27.94 (1.100)
0.05 {0.002)
Mainshatt 3rd and4th gearsLD.End play
Thickness 3rd gear4th gear
43.009 - 43.025 1 1.6933 - 1.6939)0.06 - 0.21 (0.002 - 0.008)34.92 34.97 11.375 - 1.377)31.42 - 31.4'7 11.237 , 1.2391
43.08011.6961)0.3 (0.01)
34.811.37)31.311.23)
Mainshaft sthgearLD.End play
Thickness
43.009 - 43.02511.6933 1.6939)0.06 - 0.21 (0.002 - 0.008)30.92 - 30.97 {1.217 - 1.219)
43.08011.6961)0.3 (0.01)
30.8 (1.21)
CountershaftDiameter ol needle bearing contact areaDiameter oI ball bearing and needle bearing contact
Diameter o{ 1st gear contact areaRunout
36.000 - 36.015 {1.4173 - 1.4179)24.987 - 25.000 (0.9837 - 0.9843)
36.984 - 37.00011.4561 -1.4567)
0.02 (0.001)max.
3s.95 (1.415)
24.94 (0.982)
36.93 (1.4s4)
0.0s (0.002)
countershatt 1stgearLD.End playThickness
43.009 - 43.025 (1.6933 1.6939)0.06 - 0.18 (0.002 - 0.007i26.9s,27.00 (1.061 - 1.063)
43.08 (1.696)
0.2310.009)
Countershaft 2ndgeart.D.End playThickness
47.009 - 47.025 (1.8507 - 1.8514)0.07 - 0.14 10.003 ,0.006)
2As2 - 2a.97 l1.139-1.1411
47.08 {1.854)0.18 (0.007)
Spacer collar(Mainshaft 4thand 5th gears)
t.D.o.D.Length A'ls I
le31 .002 - 31 .O12 11 .2205 , 1 .2205)37.989 - 38.000 (1.4956 1.4961)56.45 - 56.55 Q.222 - 2.226126.03,26.08 (1.025 - 1.027)
31.06 (1.223)
37.94 (1.494)
26.01 t1 .0241
Reverse idler geart.D.Gear-to-reverse gear shaft clearance20.01 6 - 20.043 (0.7880, 0.7891)0.036 - 0.084 (0.0014 - 0.0033)20.09 (0.7909)
0.16010.0063)
Synchro ringRing-to-gear clearance (ring pushed againsl gear)0.85 - r.10 (0.033 0.043)0.4 (0.02)
Dual coneClearance (ring pushed against gear)
Outer synchro ring to synchro coneSynchro cone-to-gearOuter synchro ring-to-gear
0.5 1.0 (0.02 0.04)0.5 - 1.0 (0.02 - 0.04)0.95 - 1.68 (0.037 - 0.066)
0.3 (0.01)
0.3 (0.01)
0.6 (0.02)
Shift forkFinger thickness 3rdl4th shift lorkExcept aboveFork-to-synchro sleeve clearance
7.4 - 7.6 (0.29 - 0.30)6.2 - 6.4 (0.24- 0.2s)0.35 - 0.65 (0.0't4 - 0.026)'t, torag)
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Standards and ServiceLimits
Section 14Automatic Transmission (cont'd)-
MEASUBEMENTSTANDARD {NEW}SERVICE LIMIT
TransmissionDiameter of needle bearing contact areaOn mainshaft stator shaft bearingOn mainshaft 2nd gear
On mainshaft 4th gear collarOn mainshaft 1st gear collarOn countershatt (torque converter housing side)On countershaft 3rd gear
On countershaft 4th gearOn countershaft reverse gear collarOn countershaft 1st gear collarOn sub-shaft {transmission housing sideiOn sub shaft 4th gear collarOn reverse idler gear shaftInside diameter of needle bearing contact areaOn mainshaft 1st gear
On mainshaft 2nd gearOn mainshaft 4th gear
On countershaft 1st gear
On countershaft 3rd gear
On countershaft 4th gear
On countershaft reverse gearOn sub-shaft 4th gear
On reverse idler gearfleverse idler gear shaft holder l.D.End playMainshaft 1st gearMainshaft 2nd gearMainshaft 4th gearCountershaft 1st gearCountershaft 3rd gearCountershaft 4th gear
Sub-shaft 4th gear
Reverse idler gearCountershaft reverse gear
Selector hub O.D.Mainshaft 4th gear collar lengthMainshaft 4th gear collar flange thicknessMainshaft 1st gear collar length
23.980- 23.993 (0.9441 - 0.9446)35.975 35.99'! (1.4163 1.4169)31.975 31.991 (1.2589 1.2595i30.975 - 30.991 11.2195 - 1.2201l'36.004 - 36.017 (1.4175 - 1.4180)35.980 35.996 (1.4165 1.4172)27.980 - 27.993 (1.1016 - 1.1021i31.975- 31.991 (1.2589 -'j.2595i
31.975- 31.991 (1.2589 - 1.2595)25.991 - 26.000 (1.0233 - 1.0236)22.9935 - 23.006s (0.9053 0.9058)13.990 - r4.000 (0.5508 - 0.5512)
35.000 35.016 (1.3780 1.3786)41.000 - 41.016 (1.6142 - 1.6148)38.000 - 38.016 (1.4961 -'1.4967)
38.000 - 38.016 (1.496'1 - 1.4967)41.000 41.016 (1.6142 1.6148)33.000 - 33.016 (1.2992 1.2998)38.000 - 38.016 (1.4961 - 1.4967)32.000 - 32.016 (1.2598 - 1.2605)18.007 - 18.020 (0.7089 - 0.7094)14.416 14.434 (0.5676 0.5683)
0.05 - 0.16 {0.002 - 0.006)0.05 - 0.13 (0.002 - 0.005)0.05,0.'16 (0.002 0.006)0.1 0.5 (0.004 0.020)0.05 0.17 {0.002 0.007)0.10 0.18 (0.004 0.007)0.0s 0.17 (0.002 - 0.007)0.05 - 0.18 (0.002 - 0.007)0.10,0.25(0.004 0.010)51.87 - 51.90 (2.042 - 2.043)49.50 - 49.55 (1.9488 - |.9508)4.435 4.525 (0.1746-0.1781)
27.00,27.05 {1.063'1.065i
Wear or damage
Wear or damage
Wear or damage
Wear or damage
il*=lo'. d"'.n"n"
Wear or damage
Countershaft distance collar length38.97 - 39.00 (1.534 - 1.535)39.02 39.05 (1.536, 1.537)39.07 39.10 (1.538 1.539)39.12 - 39.15 (1.540 - 1.541)39.17 - 39.20 (1.542 * 1.543)39.22 - 39.25 11.544 - 1.545)39.27 39.30 1'1.546 - 1.547i38.87 38.90 {1.530 1.531)38.92 38.95 (1.s32 1.533)
Countershaft 3rd gear collar lengthCountershaft reverse gear collar lengthCountershaft reverse gear collar flangethicknessCountershaft 1st gear collar lengthCountershaft lst gear collar flange thicknessSub-shaft 4th gear collar lengthSub shatt 4th gear collar flange thickness
21.15 - 21.20 rc.4327 - 0.4346)14.5, 14.6 (0.57't , 0.575)
2.4 - 2.6 (0.094 - 0.102)14.5 - 14.6 (0.571 - 0.575)2.4 - 2.6 (0.094 - 0.102)24.0 24.1 (0.945 0.949)2.95 - 3.10 (0.116 - 0.122)
Wear or damage
Wear or damage
Wear or damage
2-8
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2-9
Automatic Transmission - Section 14
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Unit of length: mm (in)
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MEASUREMENTSTANDARD (NEWISERVICE LIMIT
TransmissionMainshaft 2nd gear thrust washer thickness3.97 - 4.00 10.156 - 0.157)4.02 - 4.05 {0.158 - 0.159)4.07 - 4.1010.160 0.161)4.12 - 4.15 (0.162 - 0.163)4.17 4.20 (0.164 0.165)4.22 - 4.25 10.166 - 0.167 )4.27 - 4.30 (0.168 - 0.169)4.32 4.35 (0.170-0.171)
4.37 - 4.40 (0.172 0.173)4.42 - 4.45 (0.174 - 0. r75)
I
I
IWear or damage
Thrust washer thicknessl'rainshaft ball bearing left sideMainshaft 1st gear
Countershaft 3rd gear splined washerSub-shaft 4th gear thrust washer
2.95 3.05 (0.116 0.120)2.43 - 2.50 (0.096 - 0.098)4.9s - 5.00 (0.195 - 0.197)2.93 - 3.00 (0.115 - 0.1181
Wear or damage
tIWear or damage
One-way clutch contact area LD.Countershaft 1st gearParking gearMainshaft feed pipe A, O.D. (at 15 mm trom end)Mainshaft feed pipe B, O.D. (at 30 mm from end)Countershaft teed pipe O.D. lat 15 mm from end)Sub-shaft feed pipe O.D. (at 15 mm from end)Mainshatt sealing ring thickness(29 mm and 35 mm)Mainshaft bushing I.D.Mainshaft bushing l.D.Countershaft bushing l.D.Sub shatt bushing LD.Mainshaft sealing ring groove width
83.339 83.365 (3.2810 3.2821)66.685 - 66.698 (2.6254 - 2.6259)8.97 - 8.98 (0.353 - 0.354)5.97 5.98 {0.2350 - 0.2354)7.97 - 7.98 (0.3138 - 0.3142)7.97 ,7.98 (0.3138 - 0.3142)1.87 - 1.97 (0.074-0.078)
6.018 - 6.030 (0.2369 - 0.2374)9.000 - 9.015 (0.3543 - 0.3549)8.000 - 8.022 (0.3150-0.3158)
8.000 - 8.022 (0.3150 0.3158)2.025 - 2.075 (0.0797 0.0811)
Wear or damageWear or damage8.95 (0.352)
5.95 (0.234)
7.95 (0.313)
7.95 {0.313)1 .42 $.O72)
5.045 (0.2380)
9.03 (0.356)
8.03 (0.316)
8.03 (0.316)
2.095 (0.082)
ATF pumpATF pump gear side clearanceATF pump gear'to body clearance DriveDrivenATF pump driven gear LD.ATF pump driven gear shaft O.D.
0.03 - 0.05 (0.001 - 0.002)0.1050 0.1325 (0.004, 0.005)0.0350 - 0.0625 10.001 - 0.002)14.016* 14.034 (0.5518 0.5525)13.980 - 13.990 {0.5504 0.5508)
0.0710.003)
Wear or damageWear or damage
Regulatorvalve bodySealing ring contact area l.D,35.000 35.025 {1.3780 - 1.3782)35.050 (1.3799)
Stator shaftInside of diameter oI bearing contact areaOn torque convener sideOn ATF pump side2't .o00 27 .021 I '1 .063 , 1 .064)29.000 - 29.01311.r417 1.1422)Wear or damageWear or damage
Shifting device andparking brake con'trol
Reverse shitt fork finger thicknessParking brake pawl
Parking gear
5.90 - 6.00 {0.232,0.236)5.40 (0.213)
lWear or other defect
Servo bodyShift fork shatt bore l.D.Shift fork shatt valve bore l.D.14.000 - 14.010 (0.55'l2 - 0.5516)37.000 - 37.039 (1.4567 - 1.4582)37.045 (1.4585)
DifferentialcarrierPinion shaft contact area LD.Carrierto-pinion shaft clearanceDriveshafvintermediate shaft contact are l.D. 2WD4WDCarrier to driveshalt clearanceCarrier-to-intermediate shaft clearance
'18.010 - 18.028 10.709 - 0.710)0.023 - 0.057 {0.001 - 0.002}26.025 - 26.045 (1.0246 - 1.0254)28.025 - 28.045 (1.103 - 1.104)0.045 - 0.08610.002 0.003)0.075 - 0.111 10.003- 0.004)
0.r {0.004)
0.12 (0.005)
0.15 (0.006)
Differentialprnron gearBacklasht.D.Pinion gear'to-pinion shaft clearance
0.05 - 0.15 (0.002 - 0.006)18.062 - 18.066 (0.7103 - 0.7113)0.055 - 0.095 10.0022 - 0.0037)otu to.oout
Set ring-to-bearing outer race clearance0 0.15 (0 - 0.006)Adjust
TransferDiameter of roller bearing contact areaTransfer shaft (transfer gear side)Transfer shaft (middle of shaft)Transfer drive gearTransfer driven gear shaft {driven gear side)Transfer driven gear shaft {splined side)Transfer gear backlashTotalstarting torque N.m (kgf.cm, lbf.in)
38.485 38.500 (1.515 - 1.516)27 .917 - 21 .990 |.1.101 - 1.102)40.002 - 40.018 (1.575 - 1.576)35.002 35.018 (1.378 - 1.379)26.975 26.988 (1.062 -'l.063)
0.060 0.160 (0.002 - 0.006)2.64 - 3.41127.3 - 35.4,23.1 30.71
38.43 (1.513)
27.92 (1.099)
39.95 (1.573)
34.95 (1.376)
26.92 (1.060)
AdiustAdiust
(cont'd)
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Engine Block
Speciaf Tools .............7-2
lllustrated lndex ................................... 7-3
Flywheel and Drive Plate
Replacement ..,.,....7-5
Connecting Rod and Grankshaft
End Play .................7-6
Main Bearings
Cfearance ...............7 -7
Selection ................7-8
Connecting Rod Bearings
Clearance ...............7-8
Selection ................7-9
Pistons and Crankshaft
Removal .................7-9
Crankshaft
Inspection .............. 7-11
Pistons
fnspection ..............7-12
fnstaflation .............7-20
Cylinder Block
Inspection ..............7-13
Piston Pins
Removal ..,.......,,..... 7-14
Installation ............. 7-15
Inspection .............. 7-16
Connecting Rods
Selection ................7 -14
Piston Rings
End Gap .................7 -17
Ring-to-Groove Clearance ............... 7 -17
Replacement .........7-18
Alignment .............. 7-18
Crankshaft Oil Seal
lnstallation ............. 7-19
Crankshaft
lnstalfation .............7-20
Oil Seals
fnstalfation ....,..,.....7-23
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lllustrated lndex
I Luori""t" "tl internal parts with engine oil during reassembly.
Apply liquid gasket to the mating surfaces of the right side cover and oil pump case before installing them.
Jse liquid gasket, Part No. 08718 - 0001 or 08718 - 0003.
:lean the oil pan gasket mating surfaces before installing the oil pan.
WASHERReplace.
76 x 1.0 mm
y' t:n- l.zxstm, 8.7 lbl ftl
9 oIL PAN
OIL PAN GASKETReplace.
to page 1-22when installing
BEARING CAP
OOWEL PIN
CRANKSHAFT OIL SEAL
11x 1.5 mm76 N.m {7.8 kgl.m, 56 lbf.ft}Appiy engine oilto the boltthreaos.NOTE: After lorquingeach cap, turn the crankshaftto check for binding.6x1.0mm9,8 N.m (1,0 kgf.m,7 .2 tbt.lrl
n
MAIN BEARINGSSelection, page 7 8NOTE: New main bearings mustbe selected by matching the crankand block identification markings.
otL
6 x'1.0 mm9.8 N.m {1.0 kgtm,7.2 tbf.ftl
BAFFI.f PLATE
9.8 N.m 11.0 kgt m,7.2 tbt+tl
12 x 1.0 mm
/,71N n 17 .5
&it ks{ m 5a lbtft) {a/Tl
GASKETReplace.
OIL PUMP
Installation,page 7-19Replace.
ln
6WASHER IA/T}Overhaul, page 8-8Removal/lnspection,page 8-9Apply liquid gasketto mating surface.
8 x 1.25 mm
ORIVE PLATE IA/T)Check for cracks.
6x1.0mm9.8 N.m 11.0 kgt.m,7.2 lbtft)2a N.m (2.a kgt.m,---\6/
CRANIGHAFT SEALInstallation, page 8-10Replace-
6x1.0mm9.8 N.m l'1.0 kgf.m,7.2 lbf.ft)
RIGHT SIDE COVERApply liquid gasketto mating surface,
O.RINGReplace.THRUST WASHERSGrooved sides face outlvard,NOTE: Thrust washer thicknessis lixed and must not be changedby grinding or shimming.
(cont'd)
7-3
6x1.0mm
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Main Bearings
2.
3.
1.
4.
Clearance
To check main bearing-to-journal oil clearance,
remove the main caps and bearing halves.
Clean each main journal and bearing half with a
clean shop towel.
Place a strip of plastigage across each main journal.
NOTE: lf the engine is still in the vehicle when you
bolt the main cap down to check clearance, the
weight of the crankshaft and flywheel will flatten
the plastigage further than just the torque on the
cap bolt, and give you an incorrect reading. For an
accurale reading, support the crank with a jack
under the counterweights and check only one bear-
Ing aI a Irme.
Reinstall the bearings and caps, then torque the
bolts,
1st step:25 N'm (2.5 kgf.m, 18lbf.ft)
Final siep: 76 N'm 17.8 kgl.m, 56 lbf.ftl
NOTE: Do not rotate the crankshaft during inspec-
tron.
Remove the bearing cap again, and measure the
widest part of the plastigage.
Main Bearing.to.Journal Oil Clearance:
Stand8.d {New):
No. 1,2,4,5 Journsls:
0.02i1- 0.0i12 mm (0.0009 - 0.0017 inl
No. 3 Journal:
0.030 - 0.0i18 mm (0.0012 - 0.0019 inl
Service Limit: 0.06 mm 10.002 in)
lf the plastigage measures too wide or too narrow,(remove the engine if it's still in the vehicle),
remove the crankshaft, and remove the upper half
of the bearing. Install a new, complete bearing with
the same color code (select the color as shown on
the next page). and recheck the clearance, Do not
file, shim, or scrape the bearings or the caps to
adjust the clearance.
lf the plastjgage shows the clearance is still incor-
rect, try the ne)d larger or smaller bearing {the color
listed above or below that one), and check again. lf
the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace
the crankshaft and start over.
7.
7-7
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Main BearingsConnecting Rod Bearings
Selection
Crankshaft Bore Code Location
Letters have been stamDed on the end of the block as a
code Jor the size of each of the 5 main journal bores.
Use them, and the numbers or bars stamped on the
crank (codes for main journal size), to choose the correct
beanngs.
lf the codes are indecipherable because of an accumula-
tion of dirt and dust. do not scrub them with a wire
brush or sc.aper. Clean them only with solvent or deter-
gent.
Main Journ.l Cod. Locrtions lNumbcB oi Bar3l
Bearing ld.ntif icrtionColor code ison the edge ofthe bearing.
7-8
IcD
"""""""" Smallerbearing(rhicker)
Green
Green
ElaclAlue
Clearance
Remove the connecting rod cap and bearing half.
Clean the crankshaft rod journal and bearing half
with a clean shop towel.
Place the plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the
nuts.
1.
7.
Torqus: 31 N.m (3.2 kgf.m. 23 lbf.ft)
NOTE: Do not rotate the crankshaft during inspec-
tion.
Remove the rod cap and bearing half, and measure
the widest part of the plastigage.
Connesting Rod Bearing-to-Journal Oil Clearancc:
Standard {Newl: 0.020 - 0.038 mm
{0.0008 - 0.0015 in)
Service Limit: 0.05 mm {0.002 inl
lf the plastigage measures too wide or too narrow,
remove the upper half of the bearing, install a new.
complete bearing with the same color code {select
the color as shown on the next page), and recheck
the clearance. Do not file, shim, or sc.ape the bear-
ings or the caps to adjust the clearance.
lf the plastigage shows the clearance is still incor
rect, try the next larger or smaller bearing {the color
listed above or below that one). and check clear-
ance again. lf the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings. replace the crankshaft and start over.
PLASTIGAGE
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Pistons and Crankshaft
Removal (cont'dl
6. Remove the bolts. To prevent warpage, unscrew the
bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
Remove the rod caps/bearings and main caps/bear-
ings, Keep all caps/bearings in order
Lift the crankshaft out of the engine. being careful
not to damage the journals.
7.
7-10
9.
10.
Remove the upper bearing halves from the connecting
rods, and set them aside with their respective caps.
Reinstall the main caps and bearings on the engine
in proper order.
lf you can feel a ridge of metal or hard carbon
around the top of each cvlinder, remove it with a
ridge reamer. Follow the reamer manufacturer's
instructions. lf the ridge is not removed, it may
damage the pistons as they 8re pushed out.
12.
11.
14.
Use the wooden handle of a hammer to drive the
pistons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
To avoid mixup on reassembly, mark each piston/
connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.
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PistonsCrankshaft
Installation
1. Apply a coat of engine oil to the ring grooves andcylinder bores.
It the crankshaft is already installed.
2. Set the crankshatt to BDC for each cylinder.3. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of theconnecting rod bolts.
4. lnstall the ring compressor, and check that the bear-ang is securely in place.
5. Position the piston in the cylinder, and tap it in usingthe wooden handle of a hammer. Maintain down-ward force on the ring compressor to prevent ringstrom expanding before entering the cylinder bore.6. Stop after the ring compressor pops free, and checkthe connecting rod-to-crank journal alignmentbefore pushing piston into place.
7. Install the rod caps with bearings, and torque theNUIS IO:
31 N.m (3.2 kgf.m,23 tbf.ft)
Apply engine oil to the bolt threads.
lf the crankshaft is not installed:
2. Remove the rod caps and bearings, and install theflng compressor.
3. Position the piston in the cylinder, and tap it inusing the wooden handle of a hammer. Maintaindownward force on the ring compressor to prevent
rings from expanding before entering the cylinderoore,
4. Position all the pistons at top dead center.
The arrow must facethe timing belt sideof the engine.
CONNECTING ROOOIL HOLE
RUBBER HOSES
7 -20
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3.
4.
1.
6.
Installation
Apply a coat of engine oil to the main bearings androd bearings.
Insert the bearing halves in the cylinder block andconnect|ng rods.
Hold the crankshaft so the rod journals for cylindersNo.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rodjournals into connecting rods No.2 and No.3.Install the rod caps and nuts finger tight.
outward.
Rotate the crankshaft clockwise, and seat the jour
nals into connecting rods No. 1 and No. 4, Install
the rod caps and nuts finger-tight. Install the capsso the bearing recess is on the same side as therecess an the rod.
Check the rod bearing clearance with plastigage(see page 7 8). then lorque the capnuts.
Torque:
3l N.m 13.2 kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.
5.
7. Install the thrust washers on the No. 4 journal.
Line up the mark wheninstalling connecting rodcap.
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