Disassembly
1. Remove rear oil seal retainer.
Remove the 4 bolts and retainer.
2. Check connecting rod thrust clearance.
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 - 0.262 mm (0.0063 - 0.0103 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. Remove connecting rod caps and check oil clearance.
(a) Check the matchmarks on the connecting rod cap and connecting rod to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.
NOTE: Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts.
Torque:
1st: 43 Nm (35 ft lbs.)
2nd: Turn additional 90°
CAUTION: Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap. (See procedure (b) and (c)).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD: 0.032 - 0.050 mm (0.0013 - 0.0020 inch)
U/S 0.25: 0.033 - 0.073 mm (0.0013 - 0.0029 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
NOTE: If using a standard bearing, replace 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 connecting rod and crankshaft, then selecting the bearing with the same number as the total.There are 5 sizes of standard bearings, marked "2","3", "4", "5" and "6" accordingly.
Connecting rod big end inside diameter.
Mark "1": 60.526 - 60.532 mm (2.3829 - 2.3831 inch)
Mark "2": 60.532 - 60.538 mm (2.3851 - 2.3834 inch)
Mark "3": 60.538 - 60.544 mm (2.3834 - 2.3836 inch)
Crankshaft crank pin diameter.
Mark "1": 56.994 - 57.000 mm (2.2439 - 2.2441 inch)
Mark "2": 56.988 - 56.994 mm (2.2436 - 2.2439 inch)
Mark "3": 56.982 - 56.988 mm (2.2434 - 2.2436 inch)
Standard sized bearing center wall thickness.
Mark "2": 1.744 - 1.747 mm (0.0687 - 0.0688 inch)
Mark "3": 1.747 - 1.750 mm (0.0688 - 0.0689 inch)
Mark "4": 1.750 - 1.753 mm (0.0689 - 0.0690 inch)
Mark "5": 1.753 - 1.756 mm (0.0690 - 0.0691 inch)
Mark "6": 1.756 - 1.759 mm (0.0691 - 0.0693 inch)
(k) Completely remove the Plastigage.
4. Remove piston and connecting rod assemblies.
(a) Using a ridge reamer, remove the all carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
^ Keep the bearings, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in correct order.
5. Check crankshaft thrust clearance.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness:
STD: 2.440 - 2.490 mm (0.0961 -0.0980 inch)
O/S 0.125: 2.503 - 2.553 mm (0.0985 - 0.1005 inch)
O/S 0.250: 2.565 - 2.615 mm (0.1010 - 0.1030 inch)
6. Remove main bearing caps and check oil clearance.
(a) Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and (No. 4 main bearing cap only) lower thrust washers.
NOTE:
^ Keep the lower bearing and main bearing cap together.
^ Arrange the main bearing caps and lower thrust washers in correct order.
(c) Lift out the crankshaft.
NOTE: Keep the upper bearing and upper thrust washers 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, grind or 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.
Torque:
1st: 74 Nm (54 ft. lbs.)
2nd: Turn additional 90°
CAUTION: Do not turn the crankshaft.
(i) Remove the main bearing caps. (See procedure (a) and (b)).
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD: 0.036 - 0.054 mm (0.0014 - 0.0021 inch)
U/S 0.25: 0.035 - 0.075 mm (0.0014 - 0.0030 inch)
Maximum clearance: 0.10 mm (0.0039 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
NOTE: If using a standard bearing, replace 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, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "2", "3", "4", "5" and "6" accordingly.
Cylinder block main journal bore diameter.
Mark "1": 74.026 - 74.032 mm (2.9144 - 2.9146 inch)
Mark "2": 74.032 - 74.038 mm (2.9146 - 2.9149 inch)
Mark "3": 74.038 - 74.044 mm (2.9149 - 2.9151 inch)
Crankshaft journal diameter.
Mark "1": 68.994 - 69.000 mm (2.7163 - 2.7165 inch)
Mark "2": 68.988 - 68.994 mm (2.7161 - 2.7163 inch)
Mark "3": 68.982 - 68.988 mm (2.7158 - 2.7161 inch)
Standard sized bearing center wall thickness.
Mark "2": 2.492 - 2.495 mm (0.0981 - 0.0982 inch)
Mark "3": 2.495 - 2.498 mm (0.0982 - 0.0983 inch)
Mark "4": 2.498 - 2.501 mm (0.0983 - 0.0985 inch)
Mark "5": 2.501 - 2.504 mm (0.0985 - 0.0986 inch)
Mark "6": 2.504 - 2.507 mm (0.0986 - 0.0987 inch)
(k) Completely remove the Plastigage.
7. Remove crankshaft.
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust washers from the cylinder block.
NOTE: Arrange the main bearings and thrust washers in correct order.
8. Remove check valves and oil nozzles.
Remove the 6 check valves and oil nozzles.
9. Remove cylinder block orifice.