Disassembly
1. Remove rear oil seal retainer.
Remove the 6 bolts and retainer.
2. Check connecting rod thrust clearance.
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.150 - 0.330 mm (0.0059 - 0.0130 inch)
Maximum thrust clearance: 0.380 mm (0.0150 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. Remove connecting rod caps and check oil clearance.
(a) Using a punch or numbering stamp, mark the connecting rod and cap to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.
NOTE: Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts.
Torque:
1st pass: 25 Nm (18 ft. lbs.)
2nd pass: Turn additional 90°
CAUTION: Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap.
(See procedure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD: 0.024 - 0.053 mm (0.0009 - 0.0021 inch)
U/S 0.25: 0.023 - 0.069 mm (0.0009 - 0.0027 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.
NOTE: If using a standard bearing, replace with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
Reference:
Standard bearing center wall thickness:
Mark "1": 1.484 - 1.488 mm (0.0584 - 0.0586 inch)
Mark "2": 1.488 - 1.492 mm (0.0586 - 0.0587 inch)
Mark "3": 1.492 - 1.496 mm (0.0587 - 0.0589 inch)
(k) Completely remove the Plastigage.
4. Remove piston and connecting rod assemblies.
(a) Using a ridge reamer, remove the all carbon from the top of the cylinder.
(b) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(c) 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 inch)
Maximum thrust clearance: 0.300 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 - 2.490 mm (0.0961 - 0.0980 inch)
6. Remove main bearing cap and check oil clearance.
(a) Uniformly loosen and remove the main bearing cap bolts, in several passes, in the sequence shown.
(b) Using a screwdriver, pry out the main bearing cap and remove the main bearing cap, lower main bearings and lower thrust washers (No. 2 journal position of main bearing cap only).
NOTE: Keep the lower main bearings and lower thrust washers together with the main bearing cap.
(c) Lift out the crankshaft.
NOTE: Keep the upper main bearings and upper thrust washers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings.
If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing cap with the 8 bolts.
Torque:
1st pass: 61 Nm (45 ft. lbs.)
2nd pass: Turn additional 90°
CAUTION: Do not turn the crankshaft.
(i) Remove the 8 bolts and main bearing cap.
(See procedure (a) and (b) above).
(j) Measure the Plastigage at its widest point.
Standard clearance:
No. 1:
STD: 0.020 - 0.038 mm (0.0008 - 0.0015 inch)
U/S 0.25: 0.019 - 0.059 mm (0.0007 - 0.0023 inch)
Others:
STD: 0.024 - 0.042 mm (0.0009 - 0.0017 inch)
U/S 0.25: 0.023 - 0.063 mm (0.0009 - 0.0025 inch)
Maximum clearance: 0.08 mm (0.0031 inch)
NOTE: If replacing the cylinder block subassembly, the bearing standard clearance will be:
No. 1: 0.010 - 0.049 mm (0.0004 - 0.0020 inch)
Others: 0.014 - 0.053 mm (0.0006 - 0.0021 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or 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 cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4", and "5" accordingly.
Reference:
Standard sized bearing center wall thickness:
No. 1:
Mark "1": 1.991 - 1.994 mm (0.0784 - 0.0785 inch)
Mark "2": 1.994 - 1.997 mm (0.0785 - 0.0786 inch)
Mark "3": 1.997 - 2.000 mm (0.0786 - 0.0787 inch)
Mark "4": 2.000 - 2.003 mm (0.0787 - 0.0789 inch)
Mark "5": 2.003 - 2.006 mm (0.0789 - 0.0790 inch)
Others:
Mark "1": 1.989 - 1.992 mm (0.0783 - 0.0784 inch)
Mark "2": 1.992 - 1.995 mm (0.0784 - 0.0785 inch)
Mark "3": 1.995 - 1.998 mm (0.0785 - 0.0787 inch)
Mark "4": 1.998 - 2.001 mm (0.0787 - 0.0788 inch)
Mark "5": 2.001 - 2.004 mm (0.0788 - 0.0789 inch)
Cylinder block Main journal bore diameter:
Mark "1": 68.010 - 68.016 mm (2.6776 - 2.6778 inch)
Mark "2": 68.016 - 68.022 mm (2.6778 - 2.6780 inch)
Mark "3": 68.022 - 68.028 mm (2.6780 - 2.6783 inch)
Crankshaft main journal diameter:
Mark "O": 63.996 - 64.000 mm (2.5195 - 2.5197 inch)
Mark "1": 63.990 - 63.996 mm (2.5193 - 2.5195 inch)
Mark "2": 63.985 - 63.990 mm (2.5191 - 2.5193 inch)
(k) Completely remove the Plastigage.
7. Remove crankshaft.
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust washers from the cylinder block.
NOTE: Arrange the main bearings and thrust washers in correct order.