Part 1

OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
2. INSPECT CONNECTING ROD THRUST CLEARANCE

HINT: Inspect all the connecting rod thrust clearance from the cylinder head according to the procedure below.





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. INSPECT CONNECTING ROD OIL CLEARANCE

HINT: Inspect all the connecting rod oil clearance from the cylinder head according to the procedure below.

NOTICE: Do not turn the crankshaft.





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 reassembling.





b) Using SST, remove the 2 connecting rod bolts and the 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 Plastigage across the crank pin.





f) Check that the protrusion of each 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 bolts.





h) Using SST, tighten the bolts in several passes to the specified torque.
SST 09205-16010
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
i) Mark the front of each connecting rod bolts with paint.





j) Retighten the bolts 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 0.052 mm (0.0011 to 0.0020 inch)
Maximum oil clearance: 0.080 mm (0.0031 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: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

Reference:





Standard bearing center wall thickness

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) Remove the pin and connecting rod from the piston.
8. REMOVE CRANKSHAFT





a) Using a 14 mm straight hexagon wrench, remove the 4 screw plugs.
b) Remove the 10 bolts.





c) Uniformly loosen the 10 bearing cap bolts, in several passes in the sequence shown in the illustration.
SST 09011-38121





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

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

e) Remove the crankshaft from the cylinder block.
9. INSPECT 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: 0.24 mm (0.0094 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
11. REMOVE CRANKSHAFT BEARING

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

12. REMOVE STUD BOLT
13. REMOVE SUB-ASSEMBLY OIL NOZZLE NO. 1
a) Using a 5 mm socket hexagon wrench, remove the 4 oil nozzles.
14. INSPECT CYLINDER BLOCK FOR FLATNESS





a) Using a precision straight edge and feeler gauge, measure the surface that is contact with the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than maximum, replace the cylinder block.
15. INSPECT CYLINDER BORE
a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.





b) Calculate the average of thrust diameter and axial diameter at the "A" position in the illustration.
c) Calculate the average of thrust diameter and axial diameter at the "B" position in the illustration.
Standard diameter: 82.000 to 82.013 mm (3.2284 to 3.2289 inch)
If the value obtained at step (b) or (c) is not within the range of the standard diameter, replace the cylinder block.
16. INSPECT W/PIN PISTON SUB-ASSEMBLY





a) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 12 mm (0.472 inch) from the piston head.
Piston diameter: 81.975 to 81.993 mm (3.2274 to 3.2281 inch)
If the diameter is not as specified, replace the piston.
17. INSPECT PISTON OIL CLEARANCE
a) Subtract each piston diameter measurement from each cylinder bore diameter measurement.
Standard oil clearance: 0.007 to 0.038 mm (0.0003 to 0.0015 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)
^ If the oil clearance is greater than maximum, replace all the 4 pistons.
^ If necessary, replace the cylinder block.

18. INSPECT PISTON PIN OIL CLEARANCE





a) Using a caliper gauge, measure the connecting rod small end bore diameter.
Connecting rod small end bore diameter: 20.011 to 20.023 mm (0.7878 to 0.7883 inch)
If the diameter is not as specified, replace the connecting rod assembly.





b) Using a caliper gauge, measure the piston pin bore diameter.
Piston pin bore diameter: 20.013 to 20.025 mm (0.7879 to 0.7884 inch)
If the diameter is not as specified, replace the piston assembly.





c) Using a micrometer, measure the piston pin outer diameter.
Piston pin outer diameter: 20.004 to 20.016 mm (0.7876 to 0.7880 inch)
If the diameter is not as specified, replace the piston assembly.
d) Subtract each piston pin diameter measurement from the bushing inside diameter measurement.





Standard oil clearance

^ If the oil clearance is greater than maximum, replace the connecting rod.
^ If necessary, replace the piston and piston pin as a set.

19. INSPECT RING GROOVE CLEARANCE





a) Using a feeler gauge, measure the clearance between the new piston ring and wall of the ring groove.
Ring groove clearance: 0.03 to 0.07 mm (0.0012 to 0.0028 inch)
If the groove clearance is not as specified, replace the piston.
20. INSPECT PISTON RING END GAP





a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.





b) Using a feeler gauge, measure the end gap.





Standard end gap





Maximum end gap

^ If the end gap is greater than maximum, replace the piston ring.
^ If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.

21. INSPECT CONNECTING ROD SUB-ASSEMBLY
a) Using a rod aligner and feeler gauge, check the connecting rod alignments.





1) Inspect for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the misalignment is greater than maximum, replace the connecting rod assembly.





2) Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than maximum, replace the connecting rod assembly.