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: 0.15 to 0.30 mm (0.0059 to 0.0118 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
2. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check the matchmarks 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 to 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 each connecting cap bolt with paint.
j. Retighten the cap bolts 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 to 0.046 mm (0.0010 to 0.0018 inch)
Maximum oil clearance: 0.066 mm (0.0025 inch)

NOTICE: Completely remove the Plastigage.





m. If replacing a bearing, replace it with one that has the same number 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-ASSEMBLY 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 screwdriver, pry out the 2 snap rings.
7. REMOVE W/PIN PISTON SUB-ASSEMBLY





a. Gradually heat the piston to approx. 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 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the pair of the thrust washers or a crankshaft.

HINT: Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 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 the main bearing caps. Remove the 4 main bearing caps and lower bearings.





NOTICE:
^ Pull up the main bearing cap while turning it little by little to the right and the left.
^ Be careful not to damage the joint surfaces of the cylinder block and the main bearing cap.

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





12. REMOVE SUB-ASSEMBLY 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 the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If warpage is greater than the maximum, replace the cylinder block.





14. 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: 94.000 to 94.012 mm (3.7008 to 3.7013 inch)
Maximum diameter: 94.132 mm (3.7060 inch)
If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.





15. INSPECT W/PIN PISTON SUB-ASSEMBLY
a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 inch) from the piston head.
Piston diameter: 93.910 to 93.920 mm (3.6972 to 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 to 0.102 mm (0.0031 to 0.0040 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
17. INSPECT CONNECTING ROD SUB-ASSEMBLY





a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1 Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If misalignment is greater than the 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 the 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 to 22.010 mm (0.8662 to 0.8665 inch)





HINT: Piston pin hole inside diameter





b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 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 to 22.014 mm (0.8663 to 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 to 0.007 mm (0.00004 to 0.00028 inch)
Maximum oil clearance: 0.040 mm (0.0016 inch)





e. If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and piston pin together.
f. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
g. If the oil clearance is greater than the 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 to 0.011 mm (0.0002 to 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.