Part 1

OVERHAUL





1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Remove the cylinder block water drain cock from the cylinder block.





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 (0.063 - 0.0135 inch)
Maximum thrust clearance: 0.342 mm (0.0135 inch)
If the thrust clearance is greater than maximum, replace the connecting rod.
If necessary, replace the crankshaft.





3. INSPECT CONNECTING ROD 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 bolts and connecting rod cap.
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 front mark 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: 20 Nm (204 kgf-cm, 15 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 and connecting rod cap.





m. Measure the Plastigage at its widest point.
Standard oil clearance: 0.028 - 0.060 mm (0.0011 - 0.0024 inch)
Maximum oil clearance: 0.080 mm (0.0032 inch)

NOTICE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than maximum, replace the connecting rod bearing.
If necessary, grind or replace the crankshaft.








HINT: 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.





4. REMOVE CONNECTING ROD SUB-ASSY
a. Using a ride 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





5. REMOVE CONNECTING ROD BEARING
a. Remove the connecting rod bearing from the connecting rod cap.





b. Remove the connecting rod bearing from the connecting rod.





6. 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.





7. REMOVE W/PIN PISTON SUB-ASSY
a. Using a small screwdriver, pry out the 2 snap rings.





b. Heat the piston to 80 - 90°C (176 - 194°F).





c. 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 piston, pins, ring, connecting rod and bearings in the correct order.





8. REMOVE CRANKSHAFT
a. Remove the 10 bolts.





b. Uniformly loosen the 10 bearing cap bolts, in several passes, in the sequence shown in the illustration.
SST 09011-38121





c. Using a screwdriver, remove the bearing cap by prying the indicated portions between the cylinder block and bearing cap.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap.





d. Remove the crankshaft from the cylinder block.





9. 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 - 0.0095 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
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).





10. REMOVE CRANKSHAFT THRUST WASHER UPPER
a. Remove the 2 crankshaft thrust washers from the cylinder block.





11. REMOVE CRANKSHAFT BEARING
a. Remove the 5 crankshaft bearings from the cylinder block.

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





b. Remove the 5 crankshaft bearings from the bearing cap.

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

12. REMOVE STUD BOLT





a. Using torx socket wrench E5 and E7, remove the 9 stud bolts.





13. 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 maximum, replace the cylinder block.





14. 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: 79.000 - 79.013 mm (3.1102 - 3.1108 inch)
Maximum diameter: 79.013 mm (3.1108 inch)
If the diameter is greater than maximum, replace the cylinder block.





15. INSPECT W/PIN PISTON SUB-ASSY
a. Using a micrometer, measure the piston diameter at a right angle to the piston pin hole, and at the piston of 25.6 mm (1.008 inch) from the piston head.
Piston diameter: 78.872 - 78.972 mm (3.1052 - 3.1091 inch)
16. INSPECT PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.065 - 0.088 mm (0.0026 - 0.0CI35 inch)
Maximum oil clearance: 0.088 mm (0.0035 inch)
If the oil clearance is greater than maximum, replace all the pistons. If necessary, replace the cylinder block.








17. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the piston pin bore diameter.








b. Using a micrometer, measure the piston pin outer diameter.
Piston pin outer diameter: 20.004 - 20.013 mm (0.78756 - 0.78791 inch)








c. Using a caliper gauge, measure the connecting rod small end bore diameter.
Connecting rod small end bore diameter: 20.012 - 20.021 mm (0.78787 - 0.78823 inch)





d. Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance: 0.002 - 0.011 mm (0.0001 - 0.0004 inch)
Maximum oil clearance: 0.011 mm (0.0004 inch)
If the oil clearance is greater than maximum, replace the connecting rod.
If necessary, replace the w/pin piston.
e. Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance: -0.001 - 0.017 mm (-0.0004 - 0.0007 inch)
Maximum oil clearance: 0.017 mm (0.0007 inch)
If the oil clearance is greater than maximum, replace the connecting rod.
If necessary, replace the connecting rod and w/pin piston.