Part 1

CYLINDER BLOCK ASSY 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)
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. 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)
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)





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)
If warpage is greater than maximum, replace the cylinder block.





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)
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)
If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.

HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the piston with "L".

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)
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)
If the clearance is not as specified, replace the piston.
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 inch) from the top of the cylinder block.





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





Standard end gap





Maximum 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.
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)





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





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)
Subtract the piston pin diameter measurement from the piton 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)
If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.





e. 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)
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)
If out-of alignment is greater than maximum, replace the connecting rod assembly.





2 Check for 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 CONNECTING ROD BOLT
a. Using a 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.
23. INSPECT CRANKSHAFT





a. Using a dial indicator and V-blocks, measure the circle runout, ash shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the crack shaft.





b. Using a micrometer, measure the diameter of each main journal.
Diameter: 54.988 - 55.000 (2.1648 - 2.06535 inch)
c. Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)





d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 47.990 - 48.000 mm (1.8894 - 1.8898 inch)
e. Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)





24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 inch)
Minimum diameter: 7.2 mm (0.283 inch)
If the diameter is less than minimum, replace the bolt.





25. INSTALL RING PIN
a. Using a plastic-faced hammer, tap into the ring pin.
Standard protrusion:
Ring pin A 6 mm (0.236 inch)
Ring pin B 5 mm (0.197 inch)