Part 1

OVERHAUL





1. 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 - 0.362 mm (0.0063 - 0.0143 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
b. If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE

HINT: The connecting rod cap bolts are tightened in 2 progressive steps.

a. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

HINT: The matchmarks on the connecting rods and caps are for ensuring correct reassembly.





b. Using a 12 mm socket wrench, remove the 2 connecting rod cap bolts.
c. Clean the crank pin and bearing.
d. Check the crank pin and bearing for pitting and scratches.





e. Lay a strip of plastigage on the crank pin.





f. Check that the front mark 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. Using a 12 mm socket wrench, tighten the bolts in several passes by the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
i. Mark the front of the connecting rod cap bolts 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: 0.024 - 0.048 mm (0.0009 - 0.0019 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)

NOTICE: Completely remove the plastigage.





m. If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

HINT:





Standard bearing center wall thickness.





3. REMOVE PISTON SUB-ASSY W/ 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 bearing, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.

4. REMOVE CONNECTING ROD BEARING





5. 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.





6. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.
7. REMOVE PISTON





a. Gradually heat the piston to 80 - 90°C (176 - 194°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.





8. 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: 0.040 - 0.240 mm (0.0016 - 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
b. If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 1.930 - 1.980 mm (0.0760 - 0.0780 inch)

Removal:

9. REMOVE CRANKSHAFT
a. Uniformly loosen and remove the 10 bearing cap sub-assembly bolts, in several passes, in the sequence shown.
b. Remove the bearing cap and crankshaft.
10. REMOVE CRANKSHAFT THRUST WASHER UPPER
11. REMOVE CRANKSHAFT BEARING

NOTICE: Arrange the bearings in the correct order.

12. REMOVE CRANKSHAFT BEARING NO. 2

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

13. REMOVE STUD BOLT





14. 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)





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.
Standard diameter: 88.500 - 88.513 mm (3.4843 - 3.4848 inch)
Maximum diameter: 88.513 mm (3.4848 inch)
b. If the diameter is greater than maximum, replace the cylinder block.





16. INSPECT PISTON DIAMETER
a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.3 mm (1.193 inch) from the piston head.
Piston diameter: 88.439 - 88.449 mm (3.4818 - 3.4822 inch)
17. INSPECT PISTON CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.051 - 0.074 mm (0.0020 - 0.0029 inch)
Maximum oil clearance: 0.1 mm (0.0039 inch)
b. If the clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.





18. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove.
Ring groove clearance: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
19. 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 inches) from the top of the cylinder block.





b. Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.22 - 0.32 mm (0.0087 - 0.0126 inch)
No. 2 0.50 - 0.60 mm (0.0197 - 0.0236 inch)
Oil (side rail) 0.10 - 0.35 mm (0.0039 - 0.0138 inch)
Maximum end gap:
No. 1 0.89 mm (0.0350 inch)
No. 2 1.35 mm (0.0531 inch)
Oil (side rail) 0.73 mm (0.0287 inch)
20. INSPECT PISTON PIN OIL CLEARANCE





a. Using caliper gauge, measure the inside diameter of the piston bushing.
Bushing inside diameter: 22.001 - 22.010 mm (0.8662 - 0.8665 inch)

HINT:





Bushing inside diameter





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

HINT:





Piston pin diameter





c. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 inch)

HINT:





Bushing inside diameter

d. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance: 0.001 - 0.007 mm (0.00004 - 0.00028 inch)
Maximum oil clearance: 0.010 mm (0.0020 inch)





e. If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
f. Subtract the piston pin diameter measurement form the bushing inside diameter measurement.
Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch)
Maximum oil clearance: 0.010 mm (0.0020 inch)
g. If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
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)





b. If out-of alignment is greater than maximum, replace the connecting rod assembly.
1. Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
c. If twist is greater than maximum, replace the connecting rod assembly.