Part 1
OVERHAUL1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. 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 - 0.342 mm (0.0063 - 0.0135 inch)
Maximum thrust clearance: 0.342 mm (0.0135 inch)
3. INSPECT CONNECTING ROD BEARING OIL CLEARANCE
NOTICE: Do not turn the crankshaft.
a. Using marking paint, write the matched cylinder number on each connecting rod and cap.
HINT: The match marks on the connecting rods and caps are for ensuring correct reassembly.
b. Using SST, remove the 2 connecting rod cap bolts.
SST 09205-16010
c. Clean the crank pin and bearing.
d. Check the crank pin and bearing for pitting and scratches.
e. Lay a strip of plastigage across the crank pin.
f. Check that the protrusion 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 SST, tighten the bolts in several passes by the specified torque.
SST 09205-16010
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
i. Mark the front of the connecting cap bolts with paint.
j. Retighten the cap bolts by 90° as shown in the illustration.
k. Check that the crankshaft turns smoothly.
l. Remove the 2 bolts, connecting rod cap and lower bearing.
m. Measure the plastigage at its widest point.
Standard oil clearance: 0.028 - 0.052 mm (0.0011 - 0.0020 inch)
Maximum oil clearance: 0.080 mm (0.0031 inch)
NOTICE: Remove the plastigage completely after the measurement.
n. If replacing a bearing, select a new one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
Reference:
Standard bearing center wall thickness
4. REMOVE PISTON SUB-ASSY W/ CONNECTING ROD
a. 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.
5. REMOVE CONNECTING ROD BEARING
6. REMOVE PISTON RING SET
HINT: Take care not to misplace the piston rings on both the match with the piston and the direction of the rings.
a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and oil ring by hand.
7. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.
8. REMOVE W/ PIN PISTON SUB-ASSY
a. Remove the pin and connecting rod from the piston.
9. REMOVE CRANKSHAFT BEARING CAP SUB-ASSY
a. Remove the 4 screws plugs from the bearing cap sub-assembly.
b. Remove the 10 hexagon head bearing cap sub-assembly bolts.
c. Uniformly loosen the 10 bearing cap sub-assembly bolts, in several passes, in the sequence shown in the illustration.
d. Using a screwdriver, remove the bearing cap sub-assembly by prying the indicated portions between the cylinder block and bearing cap sub-assembly. Remove the 5 lower main bearings.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap sub-assembly.
SST 09011-38121
10. 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: 0.24 mm (0.0094 inch)
b. If the thrust clearance is greater than maximum, measure the thrust washer thickness. If the thickness is not specified, replace the thrust washer.
Thrust washer thickness: 2.430 - 2.480 mm (0.0957 - 0.0976 inch)
11. REMOVE CRANKSHAFT
12. REMOVE CRANKSHAFT THRUST WASHER UPPER
13. REMOVE CRANKSHAFT BEARING
NOTICE: Arrange the main bearings and thrust washers in the correct order.
14. REMOVE STUD BOLT
15. REMOVE SUB-ASSY OIL NOZZLE NO.1
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)
17. 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.
Standard diameter: 82.000 - 82.013 mm (3.2283 - 3.2289 inch)
Maximum diameter: 82.013 mm (3.2289 inch)
b. If the diameter is greater than the maximum, replace the cylinder block.
18. INSPECT PISTON DIAMETER
a. Using a micrometer, measure the piston diameter at a right angle to the piston pin hole, and at the piston of 12 mm (0.472 inch) from the piston skirt.
Piston diameter: 81.975 - 81.993 mm (3.2274 - 3.2281 inch)
19. 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: 0.05mm (0.0020 inch) per 100 mm (3.94 inch)
If twist is greater than maximum, replace the connecting rod assembly.
20. INSPECT PISTON CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.007 - 0.0138 mm (0.0003 - 0.0015 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)
b. If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.
21. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.
Ring groove clearance:
No.1: 0.020 - 0.070 mm (0.0009 - 0.0028 inch)
No.2: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
22. INSPECT PISTON RING END GAP
a. Using a piston, push the piston ring a little beyond the bottom of the ring travel, that means 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: 0.25 - 0.35 mm (0.0098 - 0.0138 inch)
No. 2: 0.35 - 0.50 mm (0.0138 - 0.0197 inch)
Oil (side rail): 0.15 - 0.40 mm (0.0059 - 0.0157 inch)
Maximum end gap:
No. 1: 1.05 mm (0.0413 inch)
No. 2: 1.20 mm (0.0472 inch)
Oil (side rail): 1.05 mm (0.0413 inch)
23. INSPECT PISTON PIN
a. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 20.011 - 20.023 mm (0.7878 - 0.7883 inch)
b. Using a caliper gauge, measure the inside diameter of the piston bushing.
Bushing inside diameter: 20.013 - 20.025 mm (0.7879 - 0.7884 inch)
c. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 20.004 - 20.016 mm (0.7876 - 0.7880 inch)
d. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance:
Piston x Piston pin 0.005 - 0.013 mm (0.0002 - 0.0005 inch)
Piston x Connecting rod 0.005 - 0.009 mm (0.0002 - 0.0004 inch)
If the oil clearance is greater than maximum. replace the connecting rod assembly. If necessary, replace the piston and piston pin as a set.
24. INSPECT CONNECTING ROD BOLT
a. Using a vernier caliper, measure the tension portion diameter of the bolts.
Standard diameter: 6.6 - 6.7 mm (0.260 - 0.264 inch)
Maximum diameter: 6.7 mm (0.263 inch)
b. If the diameter is less than minimum, replace the bolt.
25. INSPECT CRANKSHAFT
a. Using a dial indicator and V-blocks, measure the circle runout, as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
b. Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.
Diameter: 47.988 - 48.000 mm (1.8893 - 1.8898 inch)
c. Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
d. Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration.
Diameter: 44.992 - 45.000 mm (1.7713 - 1.7717 inch)
e. Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
26. INSPECT CRANKSHAFT BEARING CAP BOLT
a. Using vernier caliper, measure the tension portion diameter of the bolts.
Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 inch)
Minimum diameter: 7.3 mm (0.287 inch)
b. It the diameter is less than minimum, replace the bolt.
27. INSPECT CRANKSHAFT OIL CLEARANCE
a. Clean each main journal and bearing.
b. Place the crankshaft on the cylinder block.
c. Lay a strip of plastigage across each journal.
d. Using socket wrench (12), tighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)
e. Using socket wrench (12), retighten the bolts in several passes, in the sequence shown, by the specified torque.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
f. Mark the front of the bearing cap sub-assembly bolts with paint.
g. Retighten the bearing cap sub-assembly bolts by 45° twice, in the numerical order shown.
h. Check that the painted mark is now at a 90° angle to the front.
NOTICE: Do not turn the crankshaft.
i. Remove the bearing cap sub-assembly.
j. Measure the plastigage at its widest point.
Standard oil clearance: 0.016 - 0.032 mm (0.0006 - 0.0013 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
NOTICE: Completely remove the plastigage
k. If using standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, refer to the following table to select bearing.
Standard bearings selection chart
HINT: Cylinder block "4", Crankshaft "3", Use bearing "3"
28. INSTALL STUD BOLT
Torque:
A 5.0 Nm (51 kgf-cm, 44 inch lbs.)
B 5.0 Nm (51 kgf-cm, 44 inch lbs.)
C 5.0 Nm (51 kgf-cm, 44 inch lbs.)
D 19.0 Nm (194 kgf-cm, 14 ft. lbs.)
E 11 Nm (112 kgf-cm, 8 ft. lbs.)
29. INSTALL RING PIN
a. Using a plastic-faced hammer, tap in the new ring pins to the specified protrusion height.
Protrusion height:
A 7 mm (0.2756 inch)
B 6 mm (0.2362 inch)
C 10 mm (0.3973 inch)