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CYLINDER BLOCK ASSEMBLY
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.





6. 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: 0.150 to 0.300 mm (0.0059 to 0.0118 inch)
Maximum thrust clearance: 0.350 mm (0.0138 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crank shaft.
Connecting rod thickness: 20.80 to 20.85 mm (0.8189 to 0.8209 inch)
7. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.
c. Clean the crank pin, the bearing and the connecting rod.
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 the correct direction.
g. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.





h. Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





i. Mark the front side of each connecting cap bolt with paint.
j. Retighten the cap bolts by 90° as shown in the illustration.

NOTICE: Do not turn the crankshaft.

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





l. Measure the Plastigage at its widest point.
Standard oil clearance: 0.038 to 0.066 mm (0.0015 to 0.0026 inch)
Maximum oil clearance: 0.080 mm (0.0031 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.
m. Completely remove the Plastigage.





HINT: If replacing the bearing, replace it with one that has the same number as the connecting rod. There are 4 sizes of standard bearings: 1, 2, 3 and 4.





Standard bearing center wall thickness





8. REMOVE PISTON SUB-ASSEMBLY W/CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push out the piston and the connecting rod assembly from the top of the cylinder block.

HINT:
^ Keep the bearings, the connecting rod and the cap together.
^ Arrange the piston and the connecting rod assemblies in the correct order so they can be returned to their original locations when reassembled.

9. REMOVE CONNECTING ROD BEARING





10. 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.





11. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.
12. REMOVE W/PIN PISTON SUB-ASSEMBLY





a. Gradually heat the piston to approximately 80°C (176°F).





b. Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod.

HINT:
^ The piston and pin are a matched set.
^ Store the pistons, the pins, the rings, the connecting rods and the bearings in the correct order so that they can be returned to their original locations when re assembled.





13. 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 to 0.24 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. Check the crankshaft for wear, repair or replace if necessary.
Thrust washer thickness: 1.93 to 1.98 mm (0.0760 to 0.0780 inch)
14. INSPECT CRANKSHAFT OIL CLEARANCE





a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration.





b. Uniformly loosen and remove the 16 main bearing cap bolts in the sequence shown in the illustration.





c. Remove the 4 main bearing caps and 4 lower bearings. Also remove the 2 lower thrust washers, located under the No. 2 main bearing cap.





NOTICE: Using a screwdriver, push up on the cap little by little, alternating from the right and left side until the cap is free. 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 and lower thrust washers in the correct order.





d. Lift out the crankshaft.

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

e. Clean each main journal and bearing.
f. 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.





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





i. Install the 4 main bearing caps.

NOTICE: Do not turn the crankshaft.

j. Remove the main bearing caps (see steps (a) to (c).





k. Measure the Plastigage at its widest point.





Standard oil clearance





Maximum oil clearance

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





HINT: If using a bearing, replace it with one that has 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 refer to the table on the next page for the appropriate bearing number. The No. 1 and No. 4 journal bearings have 5 standard bearing sizes, marked 3, 4, 5, 6 and 7 accordingly. The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked 1, 2, 3, 4 and 5 accordingly.





No. 1 and No. 4 journal bearings

HINT:
EXAMPLE
Cylinder block imprinted number mark is 06
Crankshaft imprinted number mark is 08
6 + 8 = 14
Select the bearing marked "5"





No. 1 and No. 4 journal standard bearings selection chart
EXAMPLE:
Cylinder block "06", Crankshaft "08" = Use bearing "5"





No. 2 and No. 3 journal bearings

HINT:
EXAMPLE
Cylinder block imprinted number mark is 06
Crankshaft imprinted number mark is 08
6 + 8 = 14
Select the bearing marked "3"





No.2 and No.3 journal standard bearings selection chart
EXAMPLE:
Cylinder block "06", Crankshaft "08" = Use bearing "3"





Reference

l. Completely remove the Plastigage.
15. REMOVE CRANKSHAFT
a. Lift the crankshaft.
b. Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block.

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

16. REMOVE CRANKSHAFT THRUST WASHER SET
17. REMOVE CRANKSHAFT BEARING
18. 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.





19. 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.





20. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Specified diameter: 92.000 to 92.132 mm (3.6220 to 3.6272 inch)
If the measured diameters is greater than the maximum, replace the cylinder block.