Part 1

OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY





a) Remove the cylinder block water drain cock from the cylinder block.
2. CHECK CONNECTING ROD THRUST CLEARANCE





a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.342 mm (0.0063 to 0.0135 inch)
Maximum thrust clearance: 0.342 mm (0.0135 inch)
^ If the thrust clearance is greater than maximum, replace the connecting rod.
^ If necessary, replace the crankshaft.

3. CHECK CONNECTING ROD OIL CLEARANCE

NOTICE: Do not turn the crankshaft during the measurement.





a) Using marking paint, write the matched cylinder number on each connecting rod and cap.

HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.





b) Using SST, remove the 2 bolts and connecting rod cap.
SST 09205-16010
c) Clean the crank pin and bearing.
d) Check the crank pin and bearing for pitting and scratches.





e) Lay a strip of the Plastigage across the crank pin.





f) Check that the front mark of the connecting rod cap is facing in the correct direction.
g) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.





h) Using SST, tighten the bolts in several passes to the specified torque.
SST 09205-16010
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
i) Mark the front of the connecting cap bolts with paint.





j) Retighten the cap bolts by 90° as shown in the illustration.
k) Check that the crankshaft turns smoothly.





l) Remove the 2 bolts and connecting rod cap.





m) Measure the Plastigage at its widest point.
Standard oil clearance: 0.028 to 0.060 mm (0.0011 to 0.0024 inch)
Maximum oil clearance: 0.080 mm (0.0032 inch)

NOTICE: Remove the Plastigage completely after the measurement.





^ If the oil clearance is greater than maximum, replace the connecting rod bearing.
^ If necessary, grind or replace the crankshaft.

HINT:
^ The TAIHO mark is either on the claw side or the opposite side.
^ If replacing a bearing, select a new one with the same number as marked on the connecting rod bearing cap.





There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
4. REMOVE CONNECTING ROD SUB-ASSEMBLY





a) Using a ridge reamer, remove all carbon from the top of the cylinder.
b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:
^ Keep the bearing, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in the correct order.

5. REMOVE CONNECTING ROD BEARING





a) Remove the connecting rod bearing from the connecting rod cap.





b) Remove the connecting rod bearing from the connecting rod.
6. REMOVE PISTON RING SET





a) Using a piston ring expander, remove the 2 compression rings.
b) Remove the 2 side rails and oil ring by hand.
7. REMOVE W/PIN PISTON SUB-ASSEMBLY





a) Using a small screwdriver, pry out the 2 snap rings.





b) Gradually heat the piston up to 80 to 90°C (176 to 194°F).





c) Using a plastic hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod.

HINT:
^ The piston and pin are a matched set.
^ Arrange the piston, pin, ring, connecting rod and bearings in the correct order.

8. REMOVE CRANKSHAFT





a) Remove the 10 bolts from the crankshaft bearing cap.





b) Uniformly loosen the 10 bearing cap bolts in several passes in the sequence shown in the illustration.





c) Using a screwdriver, remove the crankshaft bearing cap by prying the indicated portions between the cylinder block and crankshaft bearing cap.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and crankshaft bearing cap.





d) Remove the crankshaft from the cylinder block.
9. CHECK CRANKSHAFT THRUST CLEARANCE





a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
^ If the thrust clearance is greater than maximum, measure the thrust washer thickness.
^ If the thickness is not as specified, replace the thrust washer.

HINT: Thrust washer thickness: 2.430 to 2.480 mm (0.0957 to 0.0976 inch).

10. REMOVE CRANKSHAFT THRUST WASHER UPPER





a) Remove the 2 crankshaft thrust washers from the cylinder block.
11. REMOVE CRANKSHAFT BEARING





a) Remove the 5 crankshaft bearings from the cylinder block.

NOTICE: Arrange the main bearings and thrust washers in the correct order.





b) Remove the 5 crankshaft bearings from the bearing caps.

NOTICE: Arrange the main bearings and thrust washers in the correct order.

12. REMOVE STUD BOLT





a) Using torx socket wrenches E5 and E7, remove the 9 stud bolts.
13. CHECK CYLINDER BLOCK FOR FLATNESS





a) Using a precision straight edge and feeler gauge, measure the warpage on the surface that is in contact with the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than maximum, replace the cylinder block.
14. INSPECT CYLINDER BORE





a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter: 79.000 to 79.013 mm (3.1102 to 3.1107 inch)
Maximum diameter: 79.133 mm (3.1155 inch)
If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
15. INSPECT W/PIN PISTON SUB-ASSEMBLY





a) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a piston of 28.0 mm (1.102 inch) from the top the piston head.
Piston diameter: 78.917 to 78.927 mm (3.1070 to 3.1074 inch)
If the diameter is not as specified, replace the piston assembly.
16. CHECK PISTON OIL CLEARANCE
a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.073 to 0.096 mm (0.0029 to 0.0038 inch) for 2WD
0.065 to 0.088 mm (0.0026 to 0.0035 inch) for 4WD
Maximum oil clearance:
0.10 mm (0.0039 inch) for 2WD
0.09 mm (0.0035 inch) for 4WD
^ If the oil clearance is greater than maximum, replace all pistons.
^ If necessary. replace the cylinder block.

17. CHECK PISTON PIN OIL CLEARANCE








a) Using a caliper gauge, measure the piston pin bore diameter.
Piston pin bore diameter: 20.006 to 20.015 mm (0.7876 to 0.7880 inch)
If the bore diameter is not as specified, replace the piston assembly.








b) Using a micrometer, measure the piston pin outer diameter.
Piston pin outer diameter: 20.004 to 20.013 mm (0.7876 to 0.7879 inch)
If the outer diameter is not as specified, replace the piston assembly.








c) Using a caliper gauge, measure the connecting rod small end bore diameter.
Connecting rod small end bore diameter: 20.012 to 20.021 mm (0.7879 to 0.7882 inch)
If the diameter is not as specified, replace the connecting rod assembly.





d) Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance: 0.002 to 0.011 mm (0.0001 to 0.0004 inch)
Maximum oil clearance: 0.011 mm (0.0004 inch)
^ If the oil clearance is greater than maximum, replace the connecting rod assembly.
^ If necessary, replace the piston assembly.

e) Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance: -0.001 to 0.017 mm (-0.00004 to 0.0007 inch)
Maximum oil clearance: 0.017 mm (0.0007 inch)
^ If the oil clearance is greater than maximum, replace the connecting rod assembly.
^ If necessary, replace both the connecting rod assembly and piston assembly.