Part 1

OVERHAUL

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new parts.





1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the RH and LH drain unions.
2. REMOVE WATER SEAL PLATE
a. Remove the 2 nuts.
b. Pry out the seal plate.





3. 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: 0.160 to 0.290 mm (0.0063 to 0.0138 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s).
If necessary, replace the crankshaft.
Connecting rod thickness: 22.880 to 22.920 mm (0.9008 to 0.9024 inch)





4. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check the matchmarks on the connecting rod and cap ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.





c. Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: 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, replace the crankshaft.





f. Lay a strip of Plastigage across the crank pin.





g. Install the connecting rod cap with the 2 bolts (see step 27).
h. Remove the 2 bolts, connecting rod cap and lower bearing (See steps (b) and (c) above).





i. Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 inch)
Maximum oil clearance: 0.065 mm (0.0026 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.





HINT: If using a standard bearing, replace it with one that has 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, and then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.





EXAMPLE:
Connecting rod cap 3 + Crankshaft1 = 4 (Use bearing 4)

Reference





Connecting rod big end inside diameter





Crankshaft crank pin diameter





Standard sized bearing center wall thickness

j. Completely remove the Plastigage.





5. REMOVE PISTON AND CONNECTING ROD
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.

HINT:
^ Keep the bearings, connecting rod and cap together.
^ Be sure to organize the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.





6. REMOVE W/PIN PISTON SUB-ASSEMBLY
a. Check the piston and piston pin.
1. Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin with a new piston and pin set.





b. Using a piston ring expander, remove the No. 1 and No. 2 piston rings.

HINT: Be sure to organize the removed piston rings in such a way that they can be reinstalled exactly as before.

c. Remove the 2 side rails and expander by hand.





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





e. Gradually heat the piston to approximately 60°C (140°F).





f. Using a plastic-faced hammer and brass bar, lightly tap out the piston and pin. Then remove the connecting rod.

HINT:
^ The piston and pin are a matched set.
^ Be sure to organize the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.





7. 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: 0.020 to 0.220 mm (0.0008 to 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 inch)





8. INSPECT CRANKSHAFT OIL CLEARANCE
a. Remove the 10 crankshaft bearing cap bolts.





b. Uniformly loosen and remove the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.





c. Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 crankshaft bearing cap only).

NOTICE: Be careful not to damage the cylinder block.

HINT:
^ Keep the lower bearing and bearing cap together.
^ Be sure to organize the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

d. Lift out the crankshaft.
e. Remove the 2 upper thrust washers.

HINT:
^ Be sure to organize the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
^ Keep the upper bearings together with the cylinder block.

f. Clean each crankshaft journal and bearing.
g. Check each crankshaft 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 10 crankshaft bearings and 5 crankshaft bearing caps with the 30 bolts (see step 26). Do not install the crankshaft.





i. Using a cylinder gauge, measure the inside diameter of the crankshaft bearing.
Bearing inside diameter: 66.986 to 67.000 mm (2.6372 to 2.6378 inch)
j. Measure the diameter of the crankshaft journal (see step 17).
k. Subtract the crankshaft journal diameter measurement from the crankshaft bearing inside diameter measurement.





Standard clearance





Maximum clearance

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.





HINT: If using a standard bearing, replace it with one that has 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, and then refer to the table on the next page for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For other position bearings, use bearings marked 1, 2, 3, 4 and 5.





No. 1, No. 5





Others





Reference Cylinder block crankshaft journal bore diameter (A)





Crankshaft journal diameter (B)





Standard bearing center wall thickness

No. 1 and No. 5





Others





l. Remove the 30 bolts, 5 crankshaft bearing caps and 5 lower crankshaft bearings (see steps (a) to (c) on the previous pages).
m. Remove the 5 upper crankshaft bearings from the cylinder block.

HINT: Be sure to organize the bearing caps, bearings and thrust washers in such a way that they can be reinstalled exactly as before.





9. INSPECT CYLINDER BLOCK SUB-ASSEMBLY
a. Clean the cylinder block.
1. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Using a soft brush and solvent, thoroughly clean the cylinder block.

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.





b. Inspect for flatness.
1. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than the maximum, replace the cylinder block.





c. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.





d. Inspect the cylinder bore diameter.

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

If deep scratches are present, replace the cylinder block.





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





Standard diameter

Mark 1 91.000 to 91.008 mm (3.5827 to 3.5830 inch)
Mark 2 91.008 to 91.021 mm (3.5830 to 3.5835 inch)
Mark 3 91.021 to 91.029 mm (3.5835 to 3.5838 inch)
Maximum diameter: 91.149 mm (3.5885 inch)





If the average of the diameter is greater than the maximum, replace the cylinder block.
e. Remove the cylinder ridge.
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.





10. INSPECT W/PIN PISTON SUB-ASSEMBLY
a. Clean the piston.
1. Using a gasket scraper, remove the carbon from the piston top.





2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.





3. Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.





b. Inspect the piston oil clearance.

HINT: There are 3 standard piston diameter sizes, marked 1, 2 and 3. The mark is stamped on the piston top.

1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 28.1 mm (1.106 inch) from the piston head.





Piston diameter

2. Measure the cylinder bore diameter in the thrust directions (see step 1 above).
3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.060 to 0.101 mm (0.0023 to 0.0040 inch)
Maximum oil clearance: 0.121 mm (0.0048 inch)
If the oil clearance is greater than maximum, replace all the 8 pistons. If necessary, replace the cylinder block.





HINT: Use a new cylinder block:
^ Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
^ The shape of the piston varies for the LH and RH banks. The LH piston is marked with 3L and the RH piston is marked with 3R.





c. Inspect the piston pin fit.
1. At 60°C (140°F), check that the piston pin can be pushed into the piston pin hole with your thumb.





d. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)





11. INSPECT PISTON RING SET
a. Inspect the piston ring groove clearance.
1. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.





Ring groove clearance

If the clearance is not as specified, replace the piston.





b. Inspect the piston ring end gap.
1. Insert the piston ring into the cylinder bore.
2. Using a piston, push the piston ring a little beyond the bottom of the ring travel 105 mm (4.13 inch) from the top of the cylinder block.





3. Using a feeler gauge, measure the end gap.





Standard end gap





Maximum end gap

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





12. INSPECT CONNECTING ROD SUB-ASSEMBLY
a. Using a rod aligner and feeler gauge, check the connect rod alignment.
1. Check if it is bent.
Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If bend is greater than the maximum, replace the connecting rod.





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





13. INSPECT PISTON PIN OIL CLEARANCE
a. Inspect the piston pin oil clearance.
1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)
If the bushing inside diameter is not as specified, check the oil clearance.
2. Subtract the piston pin diameter measurement (see step 10) from the bush inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and piston pin with a new piston and pin set.





14. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bush.
SST 09222-30010





15. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion of the connecting rod bolt.
Standard diameter: 7.200 to 7.300 mm (0.2835 to 0.2874 inch)
Minimum diameter: 7.00 mm (0.2756 inch)
If the diameter is less than the minimum, replace the bolt.