Part 1
OVERHAUL1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a 10 mm socket hexagon wrench, remove the screw plug.
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
a. Using a 10 mm socket hexagon wrench, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a 10 mm socket hexagon wrench, remove the screw plug.
6. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 - 0.30 mm (0.0059 - 0.0118 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
7. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.
c. Clean the crank pin, bearing and connecting rod.
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 the connecting rod cap is facing in the correct direction.
g. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
h. Tighten the bolts in several passes by the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
i. Mark the front side of the each connecting cap bolt with paint.
j. Retighten the cap bolts by 90° as shown in the illustration.
NOTICE: Do not turn the crankshaft.
k. Remove the 2 bolts, connecting rod cap and lower bearing.
l. Measure the plastigage at its widest point.
Standard oil clearance: 0.038 - 0.066 mm (0.0015 - 0.0026 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
NOTICE: Completely remove the plastigage.
m. If replace the bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1 ", "2", "3" and "4" accordingly.
HINT: Standard bearing center wall thickness
8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
9. REMOVE CONNECTING ROD BEARING
10. 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.
11. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.
12. REMOVE W/ PIN PISTON SUB-ASSY
a. Gradually heat the piston to approximately 80°C (176°F).
b. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
13. 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 - 0.24 mm (0.0016 - 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set or a crankshaft.
HINT: Thrust washer thickness 1.93 - 1.98 mm (0.0760 - 0.0780 inch)
14. REMOVE CRANKSHAFT
a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several passes, in the sequence shown.
b. Uniformly loosen and remove the 16 main bearing cap bolts in several passes, in the sequence shown.
c. Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps and lower bearings.
NOTICE:
- Pull up the main bearing cap little by little to the right and the left by turns.
- Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
15. REMOVE CRANKSHAFT THRUST WASHER SET
16. REMOVE CRANKSHAFT BEARING
17. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 inch)
If warpage is greater than maximum, replace the cylinder block
18. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 87.500 - 87.512 mm (3.4449 - 3.4453 inch)
Maximum diameter: 87.52 mm (3.4457 inch)
If the diameter is greater than maximum, replace the cylinder block.
19. INSPECT W/ PIN PISTON SUB-ASSY
a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 23.2 mm (0.913 inch) from the piston head.
Piston diameter: 87.406 - 87.416 mm (3.4412 - 3.4416 inch)
HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".
20. INSPECT PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.084 - 0.106 mm (0.0033 - 0.0042 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)
If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
21. INSPECT CONNECTING ROD SUB-ASSY
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1. Check for out-of-alignment.
Maximum out-of alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch) If out-of alignment is greater than maximum, replace the connecting rod assembly.
2. Check of twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) If twist is greater than maximum, replace the connecting rod assembly.
22. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the connecting rob bushing.
Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 inch)
b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 inch)
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 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.
23. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bushing.
SST 09222-30010
24. INSTALL CONNECTING ROD SMALL END BUSH
a. Align the oil holes of a new bushing and the connecting rod.
b. Using SST and a press, press in the bushing.
SST 09222-30010
c. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin.
Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch)
HINT: Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with thumb.
25. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Ring groove clearance:
No.1 0.02 - 0.07 mm (0.0008 - 0.0028 inch)
No.2 0.02 - 0.06 mm (0.0008 - 0.0024 inch)
Oil 0.03 - 0.11 mm (0.0011 - 0.0043 inch)
26. 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:
No. 1 0.25 - 0.35 mm (0.0098 - 0.0138 inch)
No. 2 0.35 - 0.45 mm (0.0138 - 0.0177 inch)
Oil (Side rail) 0.15 - 0.40 mm (0.0059 - 0.0157 inch)
Maximum end gap:
No. 1 0.95 mm (0.0374 inch)
No. 2 1.05 mm (0.0413 inch)
Oil (Side rail) 1.00 mm (0.0394 inch)
27. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 - 7.3 mm (0.283 - 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)
If the diameter is less than minimum, replace the bolt.
28. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.5 - 7.6 mm (0.295 - 0.299 inch)
Minimum diameter: 7.2 mm (0.283 inch)
If the diameter is less than minimum, replace the bolt.
29. INSPECT CRANKSHAFT
a. Using a dial indicator and V-blocks, measure the circle runout, as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 inch)
b. Using a micrometer, measure the diameter of each main journal.
Diameter: 60.988 - 61.000 mm (2.4011 - 2.4016 inch)
c. Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
d. Using a micrometer, measure the diameter of each crankpin.
Diameter: 52.992 - 53.000 mm (2.0863 - 2.0866 inch)
e. Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)