Disassembly
1. Remove rear oil seal retainer.
Remove the 6 bolts, retainer and gasket.
2. Check connecting rod thrust clearance.
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 - 0.25 mm (0.0059 - 0.0098 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. Remove connecting rod caps and check oil clearance.
(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.
(c) Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
NOTE: Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
CAUTION: Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bearing (See procedure (b) and (c) above).
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
STD: 0.020 - 0.048 mm (0.0008 - 0.0019 inch)
U/S 0.25: 0.019 - 0.058 mm (0.0007 - 0.0022 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
NOTE: If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
Standard sized bearing center wall thickness:
Mark "1": 1.486 - 1.490 mm (0.0585 - 0.0587 inch)
Mark "2": 1.490 - 1.494 mm (0.0587 - 0.0588 inch)
Mark "3": 1.494 - 1.498 mm (0.0588 - 0.0590 inch)
(j) Completely remove the Plastigage.
4. Remove piston and connecting rod assemblies.
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
^ Keep the bearings, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in the correct order.
5. Check crankshaft thrust clearance.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.015 - 0.220 mm (0.0006 - 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washer as a set.
Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 inch)
6. Remove main bearing caps and check oil clearance.
(a) Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No. 3 main bearing cap only).
NOTE:
^ Keep the lower bearing and main bearing cap together.
^ Arrange the main bearing caps and lower thrust washers in the correct order.
(c) Lift out the crankshaft.
NOTE: Keep the upper bearing and upper thrust washers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps.
CAUTION: Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above).
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD: 0.015 - 0.033 mm (0.0006 - 0.0013 inch)
U/S 0.25: 0.016 - 0.056 mm (0.0006 - 0.0022 inch)
Maximum clearance: 0.08 mm (O.0031 inch)
NOTE: If replacing the cylinder block subassembly, the bearing standard clearance will be:
0.015 - 0.045 mm (0.0006 - 0.0018 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
NOTE: 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 cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1","2","3","4" and "5" accordingly.
Cylinder block main journal bore diameter:
Mark 1: 52.025 - 52.031 mm (2.0482 2.0485 inch)
Mark 2: 52.031 - 52.037 mm (2.0485 2.0487 inch)
Mark 3: 52.037 - 52.043 mm (2.0487 2.0489 inch)
Crankshaft journal diameter:
Mark 0: 47.994 - 48.000 mm (1.8895 - 1.8898 inch)
Mark 1: 47.988 - 47.994 mm (1.8893 - 1.8895 inch)
Mark 2: 47.982 - 47.988 mm (1.8891 - 1.8893 inch)
Standard sized bearing center wall thickness:
Mark 1: 2.002 - 2.005 mm (0.0788 - 0.0789 inch)
Mark 2: 2.005 - 2.008 mm (0.0789 - 0.0791 inch)
Mark 3: 2.008 - 2.011 mm (0.0791 - 0.0792 inch)
Mark 4: 2.011 - 2.014 mm (0.0792 - 0.0793 inch)
Mark 5: 2.014 - 2.017 mm (0.0793 - 0.0794 inch)
(k) Completely remove the Plastigage.
7. Remove crankshaft.
(a) Lift out the crankshaft.
(b) Remove the 5 upper bearings and 2 upper thrust washers from the cylinder block.
NOTE: Arrange the main bearing caps, bearings and thrust washers in the correct order.