Part 2

DISASSEMBLY OF CYLINDER BLOCK

1. REMOVE REAR OIL SEAL RETAINER

(a) Remove the seven bolts.
(b) Remove the oil seal retainer by prying a screwdriver between the oil seal retainer and main bearing cap.
(c) Remove the 0-ring.

2. CHECK CONNECTING ROD THRUST CLEARANCE

- Using a dial indicator, measure the thrust clearance while moving the two connecting rods back and forth.

Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0114 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)

- If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 in.)

3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE

(a) Using a punch or numbering stamp, place the match- marks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the two connecting rod bolts.
(c) Using the two 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 together with the connecting rod cap.

(d) Clean the crank pin and bearings.
(e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the two bolts.

Torque:

1st 25 N.m (250 kgf.cm, 18 ft.lb)
2nd turn 90°

NOTE: Do not turn the crankshaft.

(h) Remove the two bolts, connecting rod cap and lower bearing.

(i) Measure the Plastigage at its widest point.

Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 in.)
Maximum oil clearance: 0.065 mm (0.0026 in.)
- If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

NOTE: If using a standard bearing, replace 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 connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are six sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7" accordingly.

(j) Completely remove the Plastigage.

4. REMOVE PISTON AND CONNECTING ROD AS8EMBLIES

(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 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: 0.020 - 0.220 mm (0.0008 - 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
- If the thrust clearance is greater than maximum, replace the thrust washers as a set.

Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 in.)

6. REMOVE MAIN BEARING CAP AND CHECK OIL CLEARANCE

(a) Remove the ten main bearing cap bolts.

(b) Uniformly loosen and remove the twenty main bearing cap nuts in several passes, in the sequence shown.

(c) Using two screwdrivers, pry up the main bearing caps, and remove the five main bearing caps, lower main bearings and two lower thrust washers (No.3 main bearing cap only).

NOTE: Be careful not to damage the cylinder block.

NOTE: Keep the lower main bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order.

(d) Lift out the crankshaft.
(e) Remove the two upper thrust washers.

NOTE: Arrange the upper thrust washers in correct order. Keep the upper main bearings together with the cylinder block.

(f) Clean each main journal and bearing.
(g) Check each main journal and bearing for pitting and scratches.
- If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
(h) Install the five main bearing caps with the twenty nuts and ten bolts. Do not install the crankshaft.

Torque:

Nut 1st 27 N.m (275 kgf.cm, 20 ft.lb) 2nd turn 90°
Bolt 49 N.m (500 kgf.cm, 36 ft.lb)

(i) Using a cylinder gauge, measure the inside diameter of the main bearing.

Bearing inside diameter: 67.026 - 67.033 mm (2.6388 - 2.6391 in.)

(j) Measure the diameter of the main journal.

Main journal diameter: 66.988 - 67.000 mm (2.6373 - 2.6378 in.)

(k) Subtract the main journal diameter measurement from the main bearing inside diameter measurement.

Standard oil clearance: 0.026 - 0.045 mm (0.0010 - 0.0018 in.)
Maximum clearance: 0.055 mm (0.0022 in.)
- If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

NOTE: Arrange the main bearing caps, bearings and thrust washers in correct order.

INSPECTION AND REPAIR OF CYLINDER BLOCK

1. CLEAN CYLINDER BLOCK

A. Remove gasket material. Using a gasket scraper, remove all the gasket material from the top surfaces of the cylinder block.
B. Clean cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.

NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at temperatures of 450 or less.

2. INSPECT TOP SURFACES OF CYLINDER BLOCK FOR FLATNESS
- Using a precision straight edge and feeler gauge, measure the top surfaces of the cylinder block for warpage.

Maximum warpage: 0.07 mm (0.0028 in.)
- If warpage is greater than maximum, replace the cylinder block.

3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
- Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.

4. INSPECT CYLINDER BORE DIAMETER

NOTE: There are three sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.

- Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

Standard diameter:

Mark "1" 87.500 - 87.510 mm 13.4449 - 3.4453 in.)
Mark "2" 87.510 - 67.520 mm (3.4453 - 3.4457 in.)
Mark "3" 87.520 - 87.530 mm (3.4457 - 3.4461 in.)
Maximum diameter: 87.73 mm (3.4539 in.)

- If the diameter is greater than maximum, replace the cylinder block.

5. REMOVE CYLINDER RIDGE
- If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

6. INSPECT MAIN BEARING CAP STUD BOLTS
- Using vernier calipers, measure the tension portion diameter of the stud bolt.

Standard diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 in.)
Minimum diameter: 7.40 mm (0.2913 in.)
- If the diameter is less than minimum, replace the stud bolt.

7. IF NECESSARY, REPLACE MAIN BEARING CAP STUD BOLTS

(a) Using the two main bearing cap nuts, remove the stud bolt.
(b) Apply a light coat of engine oil on the threads and under the flange of the stud bolt.
(C) Using the two main bearing cap nuts, install and torque the stud bolt.

Torque: 10 N.m, 100 kgf.cm, 7 ft.lb)

NOTE: Stud bolts come in lengths of 90.0 mm (3.543 in.) and 101.5 mm (3.996 in.). Install the 101.5 mm (3.996 in.) bolts in the inside positions. Install the 90.0 mm (3.543 in.) bolts in the outside positions.

DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES

1. CHECK FIT BETWEEN PISTON AND PISTON PIN
- Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

2. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the two compression rings.
(b) Remove the two side rails and oil ring expander by hand.

NOTE: Arrange the piston rings in correct order only.

3. DISCONNECT CONNECTING ROD FROM PISTON

(a) Using a small screwdriver, pry out the two snap rings.
(b) Gradually heat the piston to approx. 60°C (140°F).
(c) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order.

INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES

1. CLEAN PISTON

(a) Using a gasket scraper, remove the carbon from the piston top.
(b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.

NOTE: Do not use a wire brush.

2. INSPECT PISTON

A. Inspect piston oil clearance

NOTE: There are three sizes of the standard piston, marked "1","2" and "3" accordingly. The mark is stamped on the top of the piston.

Fig. 44 Piston Direction & Size Locations:

(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 49 mm (1.93 in.) from the piston head.
(b) Measure the cylinder bore diameter in the thrust directions.
(c) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance: 0.020 - 0.040 mm (0.0008 - 0.0016 in.)
Maximum oil clearance: 0.06 mm (0.0024 in.)
- If the oil clearance is greater than maximum, replace all eight pistons. If necessary, replace the cylinder block.

NOTE: (Use new cylinder block): Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block. The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".

B. Inspect piston ring groove clearance
- Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove.

Ring groove clearance:

No.1 0.020 - 0.060 mm (0.0008 - 0.0024 in.)
No.2 0.015 - 0.055 mm (0.0006 - 0.0022 in.)
- If the clearance is greater than maximum, replace the piston.

C. Inspect piston ring end gap

(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block.
(c) Using a feeler gauge, measure the ring 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.

D. Inspect piston pin fit at 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.

3. INSPECT CONNECTING ROD

A. Inspect connecting rod alignment
- Using a feeler gauge and rod aligner, check the connecting rod alignment.

Check for bend.
Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
- If bend is greater than maximum, replace the connecting rod assembly.

Check for twist.

Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
- If twist is greater than maximum, replace the connecting rod assembly.

B. Inspect connecting rod bushings

(a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

Bushing inside diameter: 22.005 - 22.017 mm (0.8663 - 0.8668 in.)

(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter: 21.997 - 22.009 mm (0.8660 - 0.8665 in.)

(c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)

C. If necessary, replace connecting rod bushings

(a) Using SST and a press, press out the bushing. SST 09222-30010
(b) Align the oil holes of the connecting rod and a new bushing.
(c) Using SST and a press, press in the bushing. SST 09222-30010
(d) Using a pin hone grinder, hone the bushing to obtain the standard specified clearance (see step B above) between the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

D. Inspect connecting rod bolts
- Using vernier calipers, measure the tension portion diameter of the bolt.

Standard diameter: 7.200 - 7.300 mm (0.2835 - 0.2874 in.)
Minimum diameter: 7.00 mm (0.2756 in.)
- If the outer diameter is less than minimum, replace the bolt.