Disassembly
1. Remove rear oil seal retainer.
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.
2. Check connecting rod thrust clearance.
Using a dial indicator, measure the thrust clearance while moving the rod back and forth.
Standard thrust clearance: 0.160 - 0.312 mm (0.0063 - 0.0123 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
3. Remove connecting rod caps and check oil clearance.
(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.
(c) Using a soft-faced hammer, lightly tap the connecting rod bolt and lift the cap and lower bearing.
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 bearing is 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: 45 Nm (460 kg.cm, 33 ft. lbs.)
2nd: Turn extra 90°
CAUTION: Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap.
(See procedure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
Standard sized: 0.030 - 0.055 mm (0.0012 - 0.0022 inch)
U/S 0.25: 0.031 - 0.071 mm (0.0012 - 0.0028 inch)
Maximum oil clearance: 0.010 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 as marked on the bearing cap. There are 3 sizes of standard bearings, marked "4", "5" and "6" accordingly.
REFERENCE:
Connecting rod big end inside diameter
Standard sized
Mark 4: 56.000 - 56.006 mm (2.2047 - 2.2050 inch)
Mark 5: 56.006 - 56.012 mm (2.2050 - 2.2052 inch)
Mark 6: 56.012 - 56.018 mm (2.2052 - 2.2054 inch)
U/S 0.25: 56.000 - 66.018 mm (2.2047 - 2.2054 inch)
Crankshaft crank pin diameter
Standard sized: 52.987 - 53.000 mm (2.0861 - 2.0866 inch)
U/S 0.25: 52.745 - 52.755 mm (2.0766 - 2.0770 inch)
Bearing center wall thickness
Standard sized
Mark 4: 1.482 - 1.485 mm (0.0583 - 0.0585 inch)
Mark 5: 1.485 - 1.488 mm (0.0585 - 0.0586 inch)
Mark 6: 1.488 - 1.491 mm (0.0586 - 0.0587 inch)
U/S 0.25: 1.601 - 1.607 mm (0.0630 - 0.0633 inch)
(k) Completely remove the Plastigage.
4. Remove piston and connecting rod assemblies.
CAUTION: Take care that the connecting rod does not touch the oil nozzle.
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Cover the rod bolts with a short piece of hose to protect the crankshaft from damage.
(c) Push out the piston and connecting rod assembly and the upper bearing though the top of the cylinder block.
NOTE:
- Keep the bearing, 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: 2.440 - 2.490 mm (0.0961 - 0.0980 inch)
6. Remove main bearing caps and check oil clearance.
(a) Uniformly loosen and remove the 10 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 lower thrust washers (No. 3 main bearing cap only).
NOTE:
- Keep the lower bearing inserted together with cap.
- Arrange the main bearing caps and lower thrust washers in correct order.
(c) Lift out the crankshaft.
NOTE: Keep the upper bearings 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 bearing. 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: 39 Nm (400 kg.cm, 29 ft. lbs.)
2nd: Turn extra 90°
CAUTION: Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
Standard sized No. 1, 2, 4, 5: 0.024 - 0.049 mm (0.0009 - 0.0019 inch)
Standard sized No. 3: 0.030 - 0.055 mm (0.0012 - 0.0022 inch)
U/S 0.25 No. 1, 2, 4, 5: 0.025 - 0.065 mm (0.0010 - 0.0026 inch)
U/S 0.25 No. 3: 0.030 - 0.070 mm (0.0012 - 0.0028 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 it with one having the same number as marked on the bearing cap. There are 3 sizes of standard bearings, marked "1", "2", "3" accordingly.
REFERENCE:
Cylinder block main journal bore diameter
Standard sized:
Mark 1: 64.004 - 64.010 mm (2.5198 - 2.5201 inch)
Mark 2: 64.011 - 64.016 mm (2.5201 - 2.5203 inch)
Mark 3: 64.017 - 64.022 mm (2.5203 - 2.5205 inch)
U/S 0.25: 64.000 - 64.024 mm (2.5197 - 2.5206 inch)
Crankshaft journal diameter
Standard sized:
No. 1, 2, 4, 5: 59.987 - 60.000 mm (2.3617 - 2.3622 inch)
No. 3: 59.981 - 59.994 mm (2.3815 - 2.3620 inch)
U/S 0.25:
No. 1, 2, 4, 5: 59.745 - 59.755 mm (2.3522 - 2.3526 inch)
No. 3: 59.740 - 59.750 mm (2.3520 - 2.3524 inch)
Bearing center wall thickness
Standard sized:
Mark 1: 1.987 - 1.990 mm (0.0782 - 0.0783 inch)
Mark 2: 1.991 - 1.993 mm (0.0784 - 0.0785 inch)
Mark 3: 1.994 - 1.996 mm (0.0785 - 0.0786 inch)
U/S 0.25: 2.106 - 2.112 mm (0.0829 - 0.0831 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 4 check valves and 4 oil nozzles.