Part 1 of 2

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: 0.15 - 0.30 mm (0.0059 - 0.0118 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
2. INSPECT CONNECTING ROD OIL CLEARANCE
a) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembling.
b) Using SST, remove the 2 connecting rod cap bolts.
SST 09011-38121
c) Clean the crank pin, bearing and connecting rod.
d) Check the crank pin and bearing for pits and scratches.





e) Lay a strip of plastigage across the crank pin.





f) Check that the protrusion of the connecting rod cap is facing the correct direction.
g) Apply a light coat of engine oil on the threads of the connecting rod cap bolts.





h) Using SST, tighten the bolts alternately with the specified torque.
SST 09011-38121
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 until 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: 0.026 - 0.046 mm (0.0010 - 0.0018 inch)
Maximum oil clearance: 0.066 mm (0.0025 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





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 in 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.

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 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.





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: 0.04 - 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 pair of the thrust washers or a crankshaft.

HINT: Thrust washer thickness 1.93 - 1.98 mm (0.0760 - 0.0780 inch)





9. REMOVE CRANKSHAFT
a) Using several steps, loosen and remove the 8 main bearing cap bolts and seal washers uniformly in the sequence as shown in the illustration.





b) Using several steps, loosen and remove the 16 main bearing cap bolts uniformly in the sequence as shown in the illustration.





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.





10. REMOVE CRANKSHAFT THRUST WASHER SET
11. REMOVE CRANKSHAFT BEARING





12. REMOVE SUB-ASSY OIL NOZZLE NO.1
a) Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles.





13. INSPECT CYLINDER BLOCK FOR FLATNESS
a) Using a precision straight edge and feeler gauge, measure flatness for the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If warpage is greater than maximum, replace the cylinder block.





14. 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.
b) Calculate the difference between the maximum diameter and the minimum diameter with the 6-measured values.
Difference limit: 0.10 mm (0.0039 inch)
(Reference)
Standard diameter: 94.000 - 94.012 mm (3.7008 - 3.7013 inch)
If the diameter is greater than limit, replace the cylinder block.





15. INSPECT W/PIN PISTON SUB-ASSY
a) Using a micrometer, measure the piston diameter at right angle to the piston pin center line, 27.7 mm (1.091 inch) from the piston head.
Piston diameter: 93.910 - 93.920 mm (3.6972 - 3.6976 inch)
16. INSPECT PISTON OIL CLEARANCE
a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.080 - 0.102 mm (0.0031 - 0.0040 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.





17. 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 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.





18. INSPECT PISTON PIN OIL CLEARANCE
a) Using a caliper gauge, measure the inside diameter of the piston pin hole.
Piston pin hole inside diameter: 22.001 - 22.010 mm (0.8662 - 0.8665 inch)





HINT: Piston pin hole 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 piton pin hole diameter measurement.
Standard oil clearance: 0.001 - 0.007 mm (0.00004 - 0.00028 inch)
Maximum oil clearance: 0.040 mm (0.0016 inch)





e) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin together. 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: 0.050 mm (0.0020 inch)
g) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together.





19. REMOVE CONNECTING ROD SMALL END BUSH
a) Using SST and a press, press out the bushing.
SST 09222-30010





20. 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 that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.





21. 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 0.07 - 0.15 mm (0.0028 - 0.0060 inch)





22. 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 0.30 - 0.40 mm (0.0118 - 0.0157 inch)
No. 2 0.40 - 0.50 mm (0.0157 - 0.0197 inch)
Oil (Side rail) 0.10 - 0.40 mm (0.0039 - 0.0157 inch)
Maximum end gap:
No. 1 1.0 mm (0.039 inch)
No. 2 1.1 mm (0.043 inch)
Oil (Side rail) 1.0 mm (0.039 inch)





23. INSPECT CONNECTING ROD BOLT
a) Using a vernier caliper, 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.





24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a) Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 10.0 - 10.2 mm (0.393 - 0.402 inch)
If the diameter is less than minimum, replace the bolt.