Part 1

OVERHAUL

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new ones.





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 to 0.290 mm (0.0063 to 0.0114 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
Connecting rod thickness (Reference): 22.880 to 22.920 mm (0.9008 to 0.9024 inch)
2. INSPECT CONNECTING ROD OIL CLEARANCE





a. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.





c. Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: Keep the lower bearing inserted with the connecting rod cap.

d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.





f. Lay a strip of Plastigage across the crank pin.





g. Match the numbered connecting rod cap with the connecting rod.
h. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.





i. Check that the outside mark of the connecting rod cap is facing in the correct direction.

HINT:
^ The connecting rod cap bolts are tightened in 2 progressive steps.
^ If any one of the connecting rod cap bolts is broken or deformed, replace it.





j. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
k. Install and alternately tighten the 2 connecting rod cap bolts in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

NOTICE: Do not turn the crankshaft.

If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.





l. Mark the front of the connecting cap bolts with paint.
m. Retighten the cap bolts 90° as shown in the illustration.
n. Check that the painted mark is now at a 90° angle to the front.





o. Remove the 2 bolts, connecting rod cap and lower bearing.





p. Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 inch)
Maximum oil clearance: 0.065 mm (0.0026 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.








HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the connecting rod cap and crankshaft, then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".

EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")





Reference
Connecting rod big end inside diameter





Crankshaft crank pin diameter





Standard sized bearing center wall thickness

q. Completely remove the Plastigage.





3. REMOVE PISTON AND 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 bearings, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in correct order.

4. REMOVE PISTON





a. Check the fitting condition between the piston and piston pin.
1 Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
b. Using a piston ring expander, remove the 2 piston rings.





c. Remove the oil ring (2 side rails and expander) by hand.

HINT: Arrange the piston rings in correct order.





d. Using a screwdriver, pry out the 2 snap rings.





e. Gradually heat the piston to approx. 60°C (140°F).





f. Using a plastic 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 correct order.

5. 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: 0.020 to 0.220 mm (0.0008 to 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.





Thrust washer thickness

6. INSPECT CRANKSHAFT OIL CLEARANCE





a. Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.





b. Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 crankshaft bearing cap only).

NOTICE: Be careful not to damage the cylinder block.

HINT:
^ Keep the lower bearing and crankshaft bearing cap together.
^ Arrange the crankshaft bearing caps and lower thrust washers in correct order.

c. Lift out the crankshaft.
d. Remove the 2 upper thrust washers.

HINT:
^ Arrange the upper thrust washers in correct order.
^ Keep the upper bearings together with the cylinder block.

e. Clean each crankshaft journal and bearing.
f. Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.





g. Place the crankshaft on the cylinder block.
h. Lay a strip of Plastigage across each journal.





i. Install the 5 crankshaft bearing caps in their proper locations.

HINT:
^ The crankshaft bearing cap bolts are tightened in 2 progressive steps (steps (k) and (m)).
^ If any one of the main bearing cap bolts is broken or deformed, replace it.





j. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
k. Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

NOTICE: Do not turn the crankshaft.

If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt.





l. Mark the front of the crankshaft bearing cap bolts with paint.
m. Retighten the crankshaft bearing cap bolts by 90° in the order shown.
n. Check that the painted mark is now at a 90° angle to the front.
o. Remove the crankshaft bearing caps.





p. Measure the Plastigage at its widest point.





Standard clearance





Maximum clearance

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.





HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the cylinder block and crankshaft, then refer to the table for the appropriate bearing number. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For the other position bearings, use bearings marked "1", "2", "3", "4" and "5".





No.1 and No.5

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5")





Others

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3")

Reference








Cylinder block crankshaft journal bore diameter (A)





Crankshaft journal diameter (B)





Standard bearing center wall thickness: No.1 and No.5





Others

q. Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
a. Lift up the crankshaft.
b. Remove the 5 upper crankshaft bearings and 2 upper thrust washers from the cylinder block.

HINT: Arrange the crankshaft bearing caps, bearings and thrust washers in correct order.

8. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY





9. CLEAN CYLINDER BLOCK SUB-ASSEMBLY
a. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
b. Using a soft brush and solvent, thoroughly clean the cylinder block.
10. INSPECT CYLINDER BLOCK SUB-ASSEMBLY





a. Inspect for warpage.
1 Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and crankshaft bearing cap.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than the maximum, replace the cylinder block sub-assembly.





b. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block.





c. Inspect the cylinder bore diameter.

HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.





1 Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.





Standard diameter

Maximum diameter: 94.230 mm (3.5917 inch)





If the diameter is greater than the maximum, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block.





d. Remove the cylinder ridge.
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.
11. INSPECT PISTON





a. Clean the piston.
1 Using a gasket scraper, remove the carbon from the piston top.





2 Using a groove cleaning tool or broken ring, clean the piston ring grooves.





3 Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.





b. Inspect the piston oil clearance.

HINT: There are 3 sizes of the standard piston diameter, marked "1", "2" or "3" accordingly. The mark is stamped on the piston top.

1 Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 inch) from the piston head.





Piston diameter





2 Measure the cylinder bore diameter in the thrust directions.
3 Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.090 to 0.111 mm (0.0035 to 0.0044 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)
If the oil clearance is greater than the maximum, replace all the 8 pistons and rebore all the 8 cylinders. If necessary, replace the cylinder block.

HINT: Use a new cylinder block:

^ Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
^ The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".





c. Inspect the piston pin fit.
1 Heat the piston to approx. 60°C (140°F), and push the piston pin into the piston pin hole with your thumb.





d. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
12. INSPECT PISTON RING SET





a. Inspect the piston ring groove clearance.
1 Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.





Ring groove clearance

If the clearance is not as specified, replace the piston.





b. Inspect the piston ring end gap.
1 Insert the piston ring into the cylinder bore.
2 Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 inch) from the top of the cylinder block.





3 Using a feeler gauge, measure the end gap.





Standard end gap





Maximum end gap

If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 8 cylinders or replace the cylinder block sub-assembly.
13. INSPECT CONNECTING ROD SUB-ASSEMBLY





a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1 Check for bend.
Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If bend is greater than the maximum, replace the connecting rod sub-assembly.





2 Check for 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 sub-assembly.





b. Inspect the piston pin oil clearance.
1 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)





2 Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
3 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: 0.05 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the connecting rod sub-assembly. If necessary, replace the piston and piston pin as a set.





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