Part 1

CYLINDER BLOCK ASSEMBLY
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 to 0.362 mm (0.0063 to 0.0143 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
If the thrust clearance is greater than the 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 that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

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

b. Using a 12 mm socket wrench, remove the 2 connecting rod cap bolts.
c. Using the 2 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 to the connecting rod cap.

d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pitting and scratches.





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





g. Check that the front mark of the connecting rod cap is facing in the correct direction.
h. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
i. Install the connecting cap (see step 37).

NOTICE: Do not turn the crankshaft.

j. Remove the 2 bolts and connecting rod cap.





k. Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.





HINT: If replacing a bearing, replace it with one that has the same number as the connecting rod. There are 3 sizes of standard bearings: 1, 2 and 3.





Standard bearing center wall thickness

l. Completely remove the Plastigage.





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 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 approximately 80 to 90°C (176 to 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 to 0.240 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 thrust washers as a set.
Thrust washer thickness: 1.930 to 1.980 mm (0.0760 to 0.0780 inch)
9. INSPECT CRANKSHAFT OIL CLEARANCE





a. Uniformly loosen and remove the 10 main bearing cap bolts, in the sequence shown in the illustration.





b. Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.

NOTICE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

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

c. Lift out the crankshaft.

HINT: Keep the upper bearings together with the cylinder block.

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





f. Place the crankshaft on the cylinder block.
g. Lay a strip of Plastigage across each journal.
h. Install the main bearing caps (see step 36).

NOTICE: Do not turn the crankshaft.

i. Remove the main bearing cap (see steps (a) to (b) above).





j. Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.048 mm (0.00094 to 0.00189 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.








k. If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then select the bearing according to the chart. There are 4 sizes of standard bearings: 1, 2, 3, and 4

HINT:
EXAMPLE
Cylinder block 4 (A) + Crankshaft 3 (B) =
Total number 7 (Use bearing 3)





Reference

l. Completely remove the Plastigage.
10. REMOVE CRANKSHAFT
a. Lift out the crankshaft.
b. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.

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

11. REMOVE CRANKSHAFT THRUST WASHER UPPER
12. REMOVE CRANKSHAFT BEARING

HINT: Arrange the bearings in the correct order.

13. REMOVE CRANKSHAFT BEARING NO.2

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

14. REMOVE STUD BOLT
15. CLEAN CYLINDER BLOCK

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.





16. 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 the warpage is greater than the maximum, replace the cylinder block.





17. 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 to 88.513 mm (3.4842 to 3.4848 inch)
Maximum diameter: 88.633 mm (3.4895 inch)
If the measured diameters is greater than the standard, replace the cylinder block.





18. 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 to 88.449 mm (3.4818 to 3.4822 inch)
19. INSPECT PISTON CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Specified oil clearance: 0.051 to 0.100 mm (0.0020 to 0.0039 inch)
If the clearance is greater than the maximum, replace all the 4 pistons. If necessary, replace the cylinder block.





20. 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 to 0.070 mm (0.0012 to 0.0028 inch)
If the clearance is not as specified, replace the piston.