ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01BASY

      Remove the oil filler cap from the cylinder head cover.

  2. REMOVE NOZZLE HOLDER SEAL


    1. A01BBWW

      Using a screwdriver, remove the holder seals by prying the portion between the holder seal and the cutout part of the cylinder head.

  3. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BAWTE01

      Remove the 10 bolts, 2 nuts, cylinder head cover and the cylinder head cover gasket.

    2. A01BGWS

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  4. REMOVE NOZZLE HOLDER CLAMP NO.1


    1. A01BEIO

      Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  5. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01BEGQ

      Remove the union bolt, 4 hollow screws, nozzle leakage pipe and 5 gaskets from the cylinder head and injector.

      Note

      Cover the nozzle leakage pipe assembly with a plastic bag to prevent foreign objects from entering to the injector.

  6. REMOVE INJECTOR ASSEMBLY


    1. A01BB6Z

      Remove the 4 injectors from the cylinder head.

      Tech Tips

      Remember the installed locations of each injector before removing them from the cylinder head.

  7. REMOVE CAMSHAFT TIMING PULLEY


    1. A01BBTF

      Remove the bolt for the camshaft timing pulley by holding the camshaft with a wrench.

    2. A01BDDQE01

      Using SST, remove the camshaft timing pulley and set key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. A01BF5DE05

      Rotate the crankshaft about 90° counterclockwise from the TDC position to lower the piston.

  8. REMOVE TIMING BELT NO.2 COVER


    1. A01BC0N

      Remove the nut, 4 bolts and timing belt No.2 cover.

  9. REMOVE NO.2 CAMSHAFT


    1. A01BHKIE01

      Face the key groove of the camshaft upward by turning the camshaft with a wrench.

    2. A01BHPHE01

      Uniformly loosen the 15 bearing cap bolts in several steps in the sequence shown in the illustration.

    3. Remove the 5 bearing caps.

    4. A01BD22

      Remove the No.2 camshaft.

  10. REMOVE CAMSHAFT


    1. A01BGX8

      Remove the camshaft.

  11. REMOVE CAMSHAFT SETTING OIL SEAL


    1. A01BCDE

      Remove the oil seal from the camshaft.

  12. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01BATEE01

      Uniformly loosen and remove the 18 cylinder head bolts in several steps in the sequence shown in the illustration.

      Note

      Head warpage or cracking could result from removing bolts in an incorrect order.

    2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

      Tech Tips

      If the cylinder head is difficult to lift off, use a screwdriver to pry between the cylinder head and block.

      Note

      Do not damage the contact surfaces of the cylinder head and cylinder block.

    3. Remove the cylinder head gasket from the cylinder block.

  13. REMOVE WATER PUMP ASSEMBLY


    1. A01BHZ7

      Remove the 5 bolts, 2 nuts, water pump and gasket.

  14. REMOVE TIMING GEAR CASE


    1. A01BCGW

      Remove the 14 bolts and 2 nuts.

    2. A01BCBA

      Pry the gear case in the location shown in the illustration.

      Note

      Do not damage the contact surface.

    3. A01BAH4

      Secure the idler sub-gears to the idler gear with a service bolt.

    4. A01BDX7

      Remove the supply pump gear.

    5. A01BGX1E01

      Remove the O-ring.

  15. INSPECT BACKLASH OF OIL PUMP GEAR TO CRANKSHAFT TIMING GEAR


    1. A01BHZL

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.20 mm (0.0079 in.)

      If the gear backlash is greater than the maximum, replace the gears as a set.

  16. INSPECT IDLE GEAR NO.1 THRUST CLEARANCE


    1. A01BF1R

      Using a dial indicator, measure the thrust clearance.

      Standard thrust clearance
      0.06 to 0.11 mm (0.0024 to 0.0043 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust plate. If necessary, replace the idle gear and/or idle gear shaft.

  17. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1


    1. A01BDK9

      Remove the crankshaft position sensor plate.

  18. INSPECT BACKLASH OF CRANKSHAFT TIMING GEAR TO IDLE GEAR NO.1


    1. A01BFZ8E01

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.20 mm (0.0079 in.)

      If the gear backlash is greater than the maximum, replace the gears as a set.

  19. REMOVE CRANKSHAFT TIMING GEAR


    1. A01BD9IE01

      Using SST, remove the crankshaft timing gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011 )

  20. INSPECT BACKLASH OF SUPPLY PUMP GEAR TO IDLE GEAR NO.1.


    1. Install the supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01BHQFE01

      Using SST, install the supply pump gear with the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 652 kgf*cm, 47 ft.*lbf }
    3. A01BBB3

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.20 mm (0.0079 in.)

      If the gear backlash is greater than the maximum, replace the gears as a set.

    4. A01BHQFE01

      Using SST, remove the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    5. A01BHFYE01

      Using SST, remove the supply pump gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

    6. Remove the 2 nuts and supply pump.

  21. REMOVE IDLE GEAR THRUST PLATE


    1. A01BCIR

      Remove the 2 bolts and thrust plate.

  22. REMOVE IDLE GEAR NO.1


    1. A01BHPR

      Turn the sub gear and align the gear teeth of the idle main gear and sub gear.

    2. Remove the idle gear and sub gear.

  23. REMOVE IDLE GEAR SHAFT NO.1


    1. A01BDKJ

      Remove the idle gear shaft.

  24. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A01BCA4

      Using a screwdriver and hammer, tap out the oil seal.

  25. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01BHMF

      Using a screwdriver and hammer, tap out the oil seal.

  26. INSPECT IDLE GEAR NO.1


    1. A01BG93

      Using a cylinder gauge, measure the inside diameter of the idle gear.

      Idle gear inside diameter
      44.000 to 44.025 mm (1.7323 to 1.7333 in.)
    2. A01BDIB

      Using a micrometer, measure the diameter of the idle gear shaft.

      Idler gear shaft diameter
      43.955 to 43.990 mm (1.7305 to 1.7319 in.)

    3. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.

      Standard oil clearance
      0.010 to 0.070 mm (0.0004 to 0.0028 in.)
      Maximum oil clearance
      0.20 mm (0.0079 in.)

      If the clearance is greater than the maximum, replace the gear and shaft.

  27. REMOVE IDLE SUB GEAR NO.2


    1. A01BEA9

      Mount the idler gear in a vise as shown in the illustration.

      Note

      Do not damage the gear.

    2. A01BB95E01

      Using snap ring pliers, remove the snap ring.

    3. A01BCV7E01

      Remove the wave washer, sub gear and gear spring.

    4. Remove the idle gear No.1 from the vise.

  28. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the drain plug and gasket.

    2. A01BEX0E01

      Remove the 22 bolts and 2 nuts.

    3. A01BC1GE01

      Insert the blade of SST between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

      Note


      • Do not use SST for the timing belt case side and rear oil seal retainer.

      • Do not damage the oil pan flange.

  29. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01BGWK

      Remove the 2 bolts, 2 nuts, oil strainer and gasket.

  30. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A01BCW5

      Remove the union bolt and 8 bolts.

    2. A01BH5PE01

      Pry the gear case in the location shown in the illustration, and remove the gear case.

      Note

      Do not drop the oil pump rotor.

    3. A01BDE1

      Remove the driven rotor and gasket.

    4. A01BAR3

      Remove the stud bolt.

    5. A01BBCJE02

      Remove the 2 O-rings.

  31. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01BCUYE01

      Remove the 5 bolts.

    2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

  32. REMOVE ENGINE REAR OIL SEAL


    1. A01BE6K

      Using a screwdriver and hammer, tap out the oil seal.

  33. INSPECT CYLINDER HEAD SET BOLT


    1. A01BGQ0E02

      Using vernier calipers, measure the minimum outer diameter of the compressed thread at the measuring point (A).

      Standard outer diameter
      11.76 to 11.97 mm (0.4630 to 0.4713 in.)
      Minimum outer diameter
      11.6 mm (0.457 in.)

      If the outer diameter is less than the minimum, replace the bolt.

    2. Check for damage to the threads of the cylinder head bolt.

    3. Check for damage to the threads of the cylinder block.

    4. Check that the 18 cylinder head bolts are installed to the cylinder block smoothly.

  34. INSPECT SUPPLY PUMP GEAR BEARING


    1. A01BC3I

      Check that the bearing is not rough or worn.

      If necessary, replace the bearing.

  35. REMOVE SUPPLY PUMP GEAR BEARING


    1. A01BETZE01

      Using SST, remove the bearing.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00390, 09951-00460, 09952-06010 )

  36. REMOVE VALVE LIFTER


    1. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the correct order.

  37. REMOVE INTAKE VALVE


    1. A01BFLLE01

      Using SST, compress the compression spring and remove the 2 keepers.

      SST
      09202-70020   ( 09202-00020 )

    2. Remove the spring retainer, compression spring, valve and spring seat.

      Tech Tips

      Arrange the valves, compression springs, spring seats and spring retainers in the correct order.

  38. REMOVE EXHAUST VALVE


    1. A01BE14E01

      Using SST, compress the compression spring and remove the 2 keepers.

      SST
      09202-70020   ( 09202-00020 )

    2. Remove the spring retainer, compression spring, valve and spring seat.

      Tech Tips

      Arrange the valves, compression springs, spring seats and spring retainers in the correct order.

  39. REMOVE VALVE STEM OIL SEAL


    1. A01BBYG

      Using needle-nose pliers, remove the oil seals.

  40. REMOVE VALVE SPRING SEAT PLATE WASHER


    1. A01BAO7

      Remove the spring seats from the cylinder head.

  41. REMOVE SEMICIRCULAR PLUG


    1. A01BE7B

      Remove the semicircular plug from the cylinder head.

  42. REMOVE STRAIGHT SCREW PLUG NO.1


    1. A01BCFA

      Using a 6 mm hexagon wrench, remove the screw plug.

      Note

      If water leaks from the w/ head straight screw plug No.1 or the plug corrodes, replace it.

  43. REMOVE STUD BOLT


    1. Remove the stud bolts from the cylinder head.

      Note

      If the stud bolt is deformed or the threads are damaged, replace it.

  44. REMOVE RING PIN


    1. Remove the ring pins from the cylinder head.

      Note

      It is not necessary to remove the ring pin unless it is being replaced.

  45. REMOVE TIGHT PLUG


    1. Remove the tight plugs from the cylinder head.

      Note

      If water leaks from the tight plug or the plug corrodes, replace it.

  46. CLEAN CYLINDER HEAD ASSEMBLY


    1. A01BBX6

      Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

      Note

      Do not scratch the cylinder block contact surface.

    2. A01BEVG

      Using a wire brush, remove all the carbon from the combustion chambers.

      Note

      Do not scratch the cylinder block contact surface.

    3. A01BESA

      Using a brush and solvent, clean all the guide bushes.

    4. A01BH6C

      Using a soft brush and solvent, thoroughly clean the cylinder head.

  47. INSPECT CYLINDER HEAD ASSEMBLY


    1. Inspect the cylinder head warpage.


      1. A01BA8IE01

        Using a precision straight edge and feeler gauge, measure the warpage on the surfaces contacting the cylinder block and the manifolds.

        Maximum warpage
        0.15 mm (0.0059 in.)

        If warpage is greater than the maximum, replace the cylinder head.

    2. Inspect the cylinder head for cracks.


      1. A01BA7W

        Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.

        If cracked, replace the cylinder head.

  48. INSPECT INTAKE VALVE SEATS


    1. A01BBGLE03

      Using a 45° carbide cutter, resurface the valve seats. Clean metal filings from the seats.

    2. Check the valve seating position.


      1. Apply a light coat of prussian blue (or white lead) to the valve face.

      2. Lightly press the valve against the seat. Do not rotate valve.

    3. Check the valve face and seat for the following:


      1. If prussian blue appears around the entire face, the valve is centered. If not, replace the valve.

      2. If prussian blue appears around the entire valve seat, the guide and face are centered. If not, resurface the seat.

      3. A01BAUDE01

        Check that the seat contact is in the middle of the valve face with the width below.

        Width
        1.2 to 1.6 mm (0.047 to 0.063 in.)

  49. INSPECT EXHAUST VALVE SEATS


    1. A01BAWDE03

      Using a 45° carbide cutter, resurface the valve seats. Clean metal filings from the seats.

    2. Check the valve seating position.


      1. Apply a light coat of prussian blue (or white lead) to the valve face.

      2. Lightly press the valve against the seat. Do not rotate valve.

    3. Check the valve face and seat for the following:


      1. If prussian blue appears around the entire face, the valve is centered. If not, replace the valve.

      2. If prussian blue appears around the entire valve seat, the guide and face are centered. If not, resurface the seat.

      3. A01BDAAE01

        Check that the seat contact is in the middle of the valve face with the width below.

        Width
        1.6 to 2.0 mm (0.063 to 0.079 in.)

  50. REPAIR INTAKE VALVE SEATS


    1. A01BDBYE09

      If the seating is too high on the valve face, use 25° and 45° cutters to correct the seat.

    2. A01BF9HE09

      If the seating is too low on the valve face, use 70° and 45° cutters to correct the seat.

    3. A01BH3T

      Handrub the valve and valve seat with an abrasive compound.

    4. After handrubbing, clean the valve and valve seat.

  51. REPAIR EXHAUST VALVE SEATS


    1. A01BDBYE10

      If the seating is too high on the valve face, use 25° and 45° cutters to correct the seat.

    2. A01BF9HE10

      If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.

    3. A01BCL1

      Handrub the valve and valve seat with an abrasive compound.

    4. After handrubbing, clean the valve and valve seat.

  52. INSPECT CAMSHAFT


    1. Inspect the circle runout.


      1. Place the camshaft on V-blocks.

      2. A01BBLV

        Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.03 mm (0.0011 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. A01BH5U

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      46.830 to 46.930 mm (1.8437 to 1.8476 in.)
      Minimum cam lobe height
      46.68 mm (1.8378 in.)

      If the cam lobe height is less than the minimum, replace the camshaft.

    3. A01BC7T

      Inspect the journal diameter of the camshaft.


      1. Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing.

        Journal diameter
        27.969 to 27.985 mm (1.1011 to 1.1018 in.)

        If the journal diameter is not as specified, check the oil clearance.

    4. Check the oil clearance.


      1. Clean the bearing caps and journals.

      2. Check the bearings for flaking and scoring.

        If the bearings are damaged, replace the bearing caps and cylinder head as a set.

      3. Install the bearings to the bearing caps and cylinder head.

      4. Place the camshaft on the cylinder head.

      5. A01BDKCE01

        Lay a strip of Plastigage across each of the journals.

      6. Install the bearing caps (see reassembly, step 43).

        Note

        Do not turn the camshaft.

      7. Remove the bearing caps.

      8. A01BG90E01

        Measure the Plastigage at its widest point.

        Standard oil clearance
        0.025 to 0.062 mm (0.0010 to 0.0024 in.)
        Maximum oil clearance
        0.10 mm (0.0039 in.)

        If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

      9. Completely remove the Plastigage.

      10. Remove the camshaft.

    5. Check the thrust clearance.


      1. Install the camshaft (see reassembly, step 43).

      2. A01BEJ6

        Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.035 to 0.185 mm (0.0014 to 0.0073 in.)
        Maximum thrust clearance
        0.25 mm (0.0098 in.)

        If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

  53. INSPECT NO.2 CAMSHAFT


    1. Inspect the circle runout.


      1. Place the camshaft on V-blocks.

      2. A01BHPK

        Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.03 mm (0.0011 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. A01BGL9

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      46.870 to 46.970 mm (1.8453 to 1.8492 in.)
      Minimum cam lobe height
      46.72 mm (1.8394 in.)

      If the cam lobe height is less than the minimum, replace the camshaft.

    3. Inspect the journal diameter of the camshaft.


      1. A01BAJU

        Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing.

        Journal diameter
        27.969 to 27.985 mm (1.1011 to 1.1018 in.)

        If the journal diameter is not as specified, check the oil clearance.

    4. Check the oil clearance.


      1. Clean the bearing caps and journals.

      2. Check the bearings for flaking and scoring.

        If the bearings are damaged, replace the bearing caps and cylinder head as a set.

      3. Install the bearings to the bearing caps and cylinder head.

      4. Place the camshaft on the cylinder head.

      5. A01BC73E01

        Lay a strip of Plastigage across each of the journals.

      6. Install the bearing caps (see reassembly, step 43).

        Note

        Do not turn the camshaft.

      7. Remove the bearing caps.

      8. A01BETDE01

        Measure the Plastigage at its widest point.

        Standard oil clearance
        0.025 to 0.062 mm (0.0010 to 0.0024 in.)
        Maximum oil clearance
        0.10 mm (0.0039 in.)

        If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

      9. Completely remove the Plastigage.

      10. Remove the camshaft.

    5. Check the thrust clearance.


      1. Install the camshaft (see reassembly, step 43).

      2. A01BFCZ

        Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.035 to 0.185 mm (0.0014 to 0.0073 in.)
        Maximum thrust clearance
        0.25 mm (0.0098 in.)

        If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

  54. INSPECT INNER COMPRESSION SPRING


    1. A01BFUDE01

      Using a steel square, measure the deviation of the spring.

      Maximum deviation
      2.0 mm (0.079 in.)

      If the deviation is greater than the maximum, replace the spring.

    2. A01BBQF

      Using vernier calipers, measure the free length of the spring.

      Free length
      46.5 mm (1.831 in.)

      If the free length is not as specified, replace the spring.

    3. A01BDCD

      Using a spring tester, measure the tension of the valve spring at the specified installed length.

      Installed tension
      (at 33.1 mm (1.303 in.)):
      150.2 to 165.8 N (15.3 to 16.9 kgf, 33.7 to 37.3 lbf)

      If the tension is not as specified, replace the spring.

  55. CLEAN INTAKE VALVE


    1. A01BBN5

      Using a gasket scraper, chip off any carbon from the valve heads.

    2. Using a wire brush, thoroughly clean the valves.

  56. INSPECT INTAKE VALVE


    1. A01BGO1

      Using a micrometer, measure the diameter of the valve stem.

      Valve stem diameter
      5.970 to 5.985 mm (0.2350 to 0.2356 in.)

      If the diameter is greater than the maximum, replace the valve and guide bushing.

    2. Grind the valve enough to remove pits and carbon.

    3. A01BD97E03

      Check that the valve is ground to the correct valve face angle.

      Valve face angle
      44.5°

      If the valve is worn, replace the valve.

    4. A01BEEZE01

      Check the valve head margin thickness.

      Standard margin thickness
      1.1 mm (0.043 in.)
      Minimum margin thickness
      0.6 mm (0.024 in.)

      If the margin thickness is less than the minimum, replace the valve.

    5. A01BHZHE01

      Check the valve overall length.

      Standard overall length
      105.38 to 105.78 mm (4.1488 to 4.1646 in.)
      Minimum overall length
      104.88 mm (4.1291 in.)

      If the overall length is less than the minimum, replace the valve.

    6. A01BHUL

      Check the surface of the valve stem tip for wear.

      Note

      Do not grind off more than the minimum.

      If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

  57. CLEAN EXHAUST VALVE


    1. A01BBN5

      Using a gasket scraper, chip off any carbon from the valve heads.

    2. Using a wire brush, thoroughly clean the valves.

  58. INSPECT EXHAUST VALVE


    1. A01BGO1

      Using a micrometer, measure the diameter of the valve stem.

      Valve stem diameter
      5.960 to 5.975 mm (0.2346 to 0.2352 in.)

      If the diameter is greater than the maximum, replace the valve.

    2. Check the valve face angle.


      1. A01BD97E03

        Grind the valve enough to remove pits and carbon.

      2. Check that the valve is ground to the correct valve face angle.

        Valve face angle
        44.5 °

        If the valve face is worn, replace the valve.

    3. A01BEEZE01

      Check the valve head margin thickness.

      Standard margin thickness
      1.1 mm (0.043 in.)
      Minimum margin thickness
      0.6 mm (0.024 in.)

      If the margin thickness is less than the minimum, replace the valve.

    4. A01BHZHE01

      Check the valve overall length.

      Standard overall length
      105.57 to 105.97 mm (4.1563 to 4.1720 in.)
      Minimum overall length
      105.07 mm (4.1366 in.)

      If the overall length is less than the minimum, replace the valve.

    5. A01BHUL

      Check the surface of the valve stem tip for wear.

      Note

      Do not grind off more than the minimum.

      If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

  59. INSPECT VALVE GUIDE BUSH OIL CLEARANCE


    1. A01BBOK

      Using a caliper gauge, measure the inside diameter of the guide bush.

      Bush inside diameter
      6.010 to 6.030 mm (0.2366 to 0.2374 in.)

      If the journal diameter is not as specified, check the oil clearance.

    2. Subtract the valve stem diameter measurement (see steps 56 and 58) from the guide bush inside diameter measurement.

      Standard oil clearance
      Clearance
      Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
      Exhaust 0.035 to 0.070 mm (0.0014 to 0.0028 in.)
      Maximum oil clearance
      Clearance
      Intake 0.08 mm (0.0031 in.)
      Exhaust 0.10 mm (0.0039 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush.

  60. REMOVE INTAKE VALVE GUIDE BUSH


    1. A01BHPD

      Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

    2. A01BC87E01

      Using SST and a hammer, tap out the valve guide bush.

      SST
      09201-10000   ( 09201-01060 )
      09950-70010   ( 09951-07100 )

  61. REMOVE EXHAUST VALVE GUIDE BUSH


    1. A01BHPD

      Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F)

    2. A01BD8UE01

      Using SST and a hammer, tap out the valve guide bush.

      SST
      09201-10000   ( 09201-01060 )
      09950-70010   ( 09951-07100 )

  62. INSTALL INTAKE VALVE GUIDE BUSH


    1. A01BFNL

      Using a caliper gauge, measure the bush bore diameter of the cylinder head.

    2. Select a new guide bush (STD or O/S 0.05).

      Bush bore diameter
      Bush size Bush bore diameter
      Use STD 10.985 to 11.006 mm (0.4325 to 0.4333 in.)
      Use O/S 0.05 11.035 to 11.056 mm (0.4344 to 0.4353 in.)

      Tech Tips


      • If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.4344 to 0.4353 in.).

      • If the bush bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head.

    3. Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

    4. A01BBEJE01

      Using SST and a hammer, tap in a new guide bush to the specified protrusion height.

      Protrusion height (H)
      10.3 to 10.7 mm (0.406 to 0.421 in.)
      SST
      09201-10000   ( 09201-01060 )
      09950-70010   ( 09951-07100 )
    5. A01BE4OE01

      Using a sharp 6.0 mm reamer, ream the guide bush to obtain the standard specified clearance (see step 59) between the guide bush and valve stem.

  63. INSTALL EXHAUST VALVE GUIDE BUSH


    1. A01BHDM

      Using a caliper gauge, measure the bush bore diameter of the cylinder head.

    2. Select a new guide bush (STD or O/S 0.05).

      Bush bore diameter
      Bush size Bush bore diameter
      Use STD 10.985 to 11.006 mm (0.4325 to 0.4333 in.)
      Use O/S 0.05 11.035 to 11.056 mm (0.4344 to 0.4353 in.)

      Tech Tips


      • If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.4344 to 0.4353 in.).

      • If the bush bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head.

    3. Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

    4. A01BAB8E01

      Using SST and a hammer, tap in a new guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01060 )
      09950-70010   ( 09951-07100 )
      Protrusion height (H)
      10.3 to 10.7 mm (0.406 to 0.421 in.)
    5. A01BFHUE01

      Using a sharp 6.0 mm reamer, ream the guide bush to obtain the standard specified clearance (see step 59) between the guide bush and valve stem.

  64. INSPECT VALVE LIFTER


    1. A01BC3A

      Using a micrometer, measure the lifter diameter.

      Lifter diameter
      30.966 to 30.976 mm (1.2191 to 1.2195 in.)
    2. A01BBIQ

      Using a caliper gauge, measure the lifter bore diameter of the cylinder head.

      Lifter bore diameter
      31.000 to 31.021 mm (1.2205 to 1.2213 in.)

      If the lifter diameter is not as specified, check the oil clearance.

    3. Subtract the lifter diameter measurement from the lifter bore diameter measurement.

      Standard oil clearance
      0.024 to 0.055 mm (0.0009 to 0.0022 in.)
      Maximum oil clearance
      0.075 mm (0.0030 in.)

      If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head.

  65. REMOVE CYLINDER BLOCK OIL ORIFICE


    1. A01BCEKE01

      Remove the cylinder block oil orifice from the cylinder block.

  66. INSPECT CYLINDER BLOCK OIL ORIFICE


    1. Check the oil orifice for damage or clogging.

      If necessary, replace the oil orifice.

  67. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01BC3X

      Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.100 to 0.300 mm (0.0039 to 0.0118 in.)
      Maximum thrust clearance
      0.40 mm (0.0157 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

  68. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01BBX0E01

      Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

    2. Remove the 2 connecting road cap bolts.

    3. A01BEWR

      Using the 2 removed connecting rod bolts, pry the connecting rod cap back and forth, and remove the connecting cap.

      Tech Tips

      Keep the lower bearing inserted with the connecting rod cap.

    4. Clean the crank pin and bearing.

    5. 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.

    6. A01BEYBE01

      Lay a strip of Plastigage across the crank pin.

    7. Install the connecting rod cap with the 2 bolts (see reassembly, step 13).

      Note

      Do not turn the crankshaft.

    8. Remove the 2 bolts, connecting rod cap and lower bearing (see steps (b) and (c) above).

    9. A01BABUE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Size Clearance
      STD 0.036 to 0.054 mm (0.0014 to 0.0021 in.)
      U/S 0.25, U/S 0.50 0.037 to 0.077 mm (0.0015 to 0.0030 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

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

      Tech Tips

      If using a standard 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 crankshaft and connecting rod, then select the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

      EXAMPLE:

      Connecting rod cap "3" + Crankshaft "1" =

      Total number 4 (Use bearing "4")

      Reference
      Connecting rod big end inner diameter
      Mark Diameter
      1 62.014 to 62.020 mm (2.4415 to 2.4417 in.)
      2 62.020 to 62.026 mm (2.4417 to 2.4420 in.)
      3 62.026 to 62.032 mm (2.4420 to 2.4422 in.)
      Crankshaft pin diameter
      Mark Diameter
      1 58.994 to 59.000 mm (2.3226 to 2.3228 in.)
      2 58.988 to 58.994 mm (2.3224 to 2.3226 in.)
      3 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
      Standard sized bearing center wall thickness
      Mark Bearing center wall thickness
      2 1.486 to 1.489 mm (0.0585 to 0.0586 in.)
      3 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
      4 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
      5 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
      6 1.498 to 1.501 mm (0.0590 to 0.0591 in.)

    10. Completely remove the Plastigage.

  69. REMOVE CONNECTING ROD BEARING


    1. A01BB8JE01

      Using a ridge reamer, remove all the carbon from the top of the cylinder.

    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

      Tech Tips


      • Keep the bearings, connecting rod and cap together.

      • Be sure to organize the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

  70. INSPECT PISTON W/CONNECTING ROD


    1. Check the fitting condition between the piston and piston pin.


      1. A01BD2IE02

        Try to move the piston back and forth on the piston pin.

        If any movement is felt, replace the piston and pin with a new piston and pin as a set.

  71. REMOVE PISTON RING SET


    1. A01BEN6

      Using a piston ring expander, remove the 2 compression rings.

      Tech Tips

      Be sure to organize the removed piston rings in such a way that they can be reinstalled exactly as before.

    2. Remove the coil and oil ring by hand.

  72. REMOVE PISTON SUB-ASSEMBLY W/PIN


    1. Disconnect the connecting rod from the piston.


      1. A01BFSV

        Using a screwdriver, pry off the 2 snap rings from the piston.

      2. A01BDTZE04

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

      3. A01BHA6

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

        Tech Tips


        • The piston and pin are a matched set.

        • Be sure to organize the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.

  73. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01BE08

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.040 to 0.240 mm (0.0016 to 0.0098 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

      Thrust washer thickness
      Size Thickness
      STD 2.430 to 2.480 mm (0.0957 to 0.0976 in.)
      O/S 0.125 2.555 to 2.605 mm (0.1005 to 0.1025 in.)
      O/S 0.250 2.680 to 2.730 mm (0.1055 to 0.1074 in.)

  74. INSPECT CRANKSHAFT OIL CLEARANCE


    1. A01BDRXE01

      Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps, in the sequence shown in the illustration.

    2. A01BHIJ

      Using the removed crankshaft bearing cap bolts, pry the cap back and forth, and remove the crankshaft bearing caps, lower crankshaft bearings and lower thrust washers (No. 5 crankshaft bearing cap only).

      Tech Tips


      • Keep the lower bearing and crankshaft bearing cap together.

      • Be sure to organize the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

    3. Lift out the crankshaft.

      Tech Tips

      Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.

    4. Clean each crankshaft journal and bearing.

    5. Check each crankshaft journal and bearing for pitting and scratches.

      If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

    6. Place the crankshaft on the cylinder block.

    7. A01BH3NE01

      Lay a strip of Plastigage across each journal.

    8. A01BDRXE02

      Install the 5 crankshaft bearing caps with the 10 bolts (see reassembly, step 12).

      Note

      Do not turn the crankshaft.

    9. Remove the 10 bolts and 5 crankshaft bearing caps (see steps (a) and (b) above).

    10. A01BBWHE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Size Oil clearance
      STD 0.030 to 0.048 mm (0.0012 to 0.0019 in.)
      O/S 0.25, O/S 0.50 0.037 to 0.077 mm (0.0015 to 0.0030 in.)
      Maximum clearance
      0.10 mm (0.0039 in.)

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

      Tech Tips

      If replacing the cylinder block sub-assembly, the bearing standard clearance will be within the standard value.

      Standard
      0.030 to 0.048 mm (0.0012 to 0.0019 in.)

      Tech Tips

      If using a standard bearing, replace it 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 select the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

      Reference
      Cylinder block main journal bore diameter
      Mark Diameter
      1 75.000 to 75.006 mm (2.9528 to 2.9530 in.)
      2 75.006 to 75.012 mm (2.9530 to 2.9532 in.)
      3 75.012 to 75. 018 mm (2.9532 to 2.9535 in.)
      Crankshaft journal diameter
      Mark Diameter
      1 69.994 to 70.000 mm (2.7557 to 2.7559 in.)
      2 69.988 to 69.994 mm (2.7554 to 2.7557 in.)
      3 69.982 to 69.988 mm (2.7552 to 2.7554 in.)
      Standard sized bearing center wall thickness
      Mark Bearing center wall thickness
      2 2.482 to 2.485 mm (0.0977 to 0.0978 in.)
      3 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
      4 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      5 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      6 2.494 to 2.497 mm (0.0982 to 0.0983 in.)

    11. Completely remove the Plastigage.

  75. REMOVE CRANKSHAFT


    1. Lift out the crankshaft.

    2. Remove the upper bearings and upper thrust washers from the cylinder block.

      Tech Tips

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

  76. REMOVE OIL NOZZLE NO.1 SUB-ASSEMBLY


    1. A01BDIU

      Remove the 4 check valves and oil nozzles.

  77. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A01BAPAE01

      Push the valve with a wooden stick to check if it is stuck.

      Tech Tips

      If stuck, replace the check valve.

  78. REMOVE SCREW PLUG


    1. Remove the screw plug and gasket.

  79. CLEAN CYLINDER BLOCK ASSEMBLY


    1. A01BEJY

      Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

    2. Using a soft brush and solvent, thoroughly clean the cylinder block.

      Note

      Protect your eyes when using high pressure compressed air.

  80. INSPECT CYLINDER BLOCK ASSEMBLY


    1. Inspect for warpage.


      1. A01BHQE

        Using a precision straight edge and feeler gauge, measure the warpage on the surface contacting the cylinder head cap.

        Maximum warpage
        0.10 mm (0.0039 in.)

        If warpage is greater than the maximum, replace the cylinder block.

    2. A01BGTA

      Visually check the cylinder for vertical scratches.

      If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

    3. A01BFJGE01

      Inspect the cylinder bore diameter.

      Tech Tips

      There are 3 sizes of the standard cylinder bore diameter, marked 1, 2 and 3 accordingly. The mark is stamped on the lower left rear of the cylinder block.


      1. A01BFSPE07

        Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

        Standard diameter
        Mark Diameter
        1 92.000 to 92.010 mm (3.6220 to 3.6224 in.)
        2 92.010 to 92.020 mm (3.6224 to 3.6228 in.)
        3 92.020 to 92.030 mm (3.6228 to 3.6232 in.)
        Maximum diameter
        92.23 mm (3.6311 in.)

        If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

    4. A01BB8JE01

      Inspect the cylinder ridge.

      Tech Tips

      If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

  81. CLEAN PISTON


    1. A01BI2W

      Using a gasket scraper, remove the carbon from the piston top.

    2. A01BHKR

      Using a groove cleaning tool or broken ring, clean the piston ring grooves.

    3. A01BF9Z

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  82. INSPECT PISTON SUB-ASSEMBLY W/PIN

    Tech Tips


    • When replacing the piston sub-assembly w/pin with a supply part, there are a number of piston diameter size to choose from, but there is only one size of piston pin diameter.

    • There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top.


    1. Inspect the piston oil clearance.


      1. A01BCJ2E01

        Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston head.

        Distance
        65 mm (2.5591 in.)
        Piston diameter
        - - Diameter
        STD Mark 1 91.920 to 91.930 mm (3.6189 to 3.6193 in.)
        STD Mark 2 91.931 to 91.940 mm (3.6193 to 3.6197 in.)
        STD Mark 3 91.941 to 91.950 mm (3.6197 to 3.6201 in.)
        STD O/S 0.50 92.42 to 92.45 mm (3.6386 to 3.6398 in.)

        Tech Tips

        The piston should be installed to the block which has the same mark with the piston.

      2. Measure the cylinder bore diameter in the thrust directions (see step 80).

      3. A01BC7LE01

        Subtract the piston diameter measurement from the cylinder bore diameter measurement.

        Standard oil clearance
        0.070 to 0.090 mm (0.0028 to 0.0035 in.)
        Maximum oil clearance
        0.16 mm (0.0063 in.)

        If the oil clearance is greater than the maximum, replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block.

        Tech Tips


        • Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.

        • Bore all the 4 cylinders for the O/S piston outside diameter.

        • Replace all the piston rings with ones to match the O/S pistons.

    2. Prepare 4 new O/S pistons.

      O/S 0.50 piston diameter
      92.42 to 92.45 mm (3.6386 to 3.6398 in.)
    3. A01BCJ2E01

      Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston head.

      Distance
      65 mm (2.5591 in.)

    4. Calculate the amount each cylinder is to be rebored as follows:

      Size to be rebored = P + C - H:
      P Piston diameter
      C Piston clearance: 0.070 to 0.090 mm (0.0028 to 0.0035 in.)
      H Allowance for honing: 0.02 mm (0.0008 in.) or less

    5. Bore and hone the cylinders to calculated dimensions.

      Maximum honing
      0.02 mm (0.0008 in.)

      Note

      Excess honing will destroy the finished roundness.

    6. A01BHIS

      Using a micrometer, measure the piston pin diameter.

      Piston pin diameter
      Mark Diameter
      A 33.996 to 34.000 mm (1.3384 to 1.3385 in.)
      B 34.001 to 34.004 mm (1.3385 to 1.3387 in.)
      C 34.005 to 34.008 mm (1.3387 to 1.3388 in.)

    7. Inspect the piston pin fit.


      1. A01BH0R

        Heat the piston to 80°C (176°F), and push the piston pin into the piston pin hole with your thumb.

        If the pin can be installed at a lower temperature, replace the piston and pin as a set.

  83. INSPECT PISTON RING SET


    1. A01BATK

      Inspect the piston ring groove clearance.


      1. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

        Standard groove clearance
        Ring Groove clearance
        No. 1 0.060 to 0.100 mm (0.0024 to 0.0039 in.)
        No. 2 0.050 to 0.090 mm (0.0020 to 0.0035 in.)
        Oil 0.030 to 0.075 mm (0.0012 to 0.0030 in.)
        Maximum groove clearance
        0.20 mm (0.0079 in.)

        If the clearance is greater than the maximum, replace the piston.

    2. Inspect the piston ring end gap.


      1. Insert the piston ring into the cylinder bore.

      2. A01BI10E01

        Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block.

      3. A01BEEG

        Using a feeler gauge, measure the end gap.

        Standard end gap
        Ring End gap
        No. 1 0.390 to 0.510 mm (0.0106 to 0.0154 in.)
        No. 2 0.470 to 0.620 mm (0.0185 to 0.0244 in.)
        Oil 0.200 to 0.400 mm (0.0079 to 0.0157 in.)
        Maximum end gap
        Ring End gap
        No. 1 1.21 mm (0.0476 in.)
        No. 2 1.44 mm (0.0567 in.)
        Oil 1.22 mm (0.0480 in.)

        If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

  84. INSPECT CONNECTING ROD SUB-ASSEMBLY


    1. A01BAFH

      Using a rod aligner and feeler gauge, check the connecting rod alignment.


      1. Check if the rod is bent.

        Maximum bend
        0.03 mm (0.0012 in.) per 100 mm (3.94 in.)

        If bend is greater than the maximum, replace the connecting rod sub-assembly.

      2. A01BBO8

        Check if the rod is twisted.

        Maximum twist
        0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

        If twist is greater than the maximum, replace the connecting rod sub-assembly.

  85. INSPECT PISTON PIN OIL CLEARANCE

    Tech Tips

    When replacing the piston sub-assembly w/pin with a supply part, there are a number of piston diameter size to choose from, but there is only one size of piston pin diameter.


    1. Inspect the piston pin oil clearance.


      1. A01BHMDE01

        Using a caliper gauge, measure the inside diameter of the connecting rod bush.

        Connecting rod bush inside diameter
        Mark Diameter
        A 34.012 to 34.016 mm (1.3390 to 1.3392 in.)
        B 34.017 to 34.020 mm (1.3392 to 1.3393 in.)
        C 34.021 to 34.024 mm (1.3394 to 1.3395 in.)

      2. Subtract the piston pin diameter measurement (see step 82) from the bush inside diameter measurement.

        Standard oil clearance
        0.012 to 0.020 mm (0.0005 to 0.0009 in.)
        Maximum oil clearance
        0.03 mm (0.0012 in.)

        If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and piston pin with a new piston and pin set.

  86. REMOVE CONNECTING ROD SMALL END BUSH


    1. A01BDWAE01

      Using SST and a press, press out the bush.

      SST
      09222-76012

  87. INSPECT CONNECTING ROD BOLT


    1. A01BE9WE02

      Using vernier calipers, measure the diameter of the tension portion of the connecting rod bolt.

      Standard diameter
      8.500 to 8.600 mm (0.3346 to 0.3385 in.)
      Minimum diameter
      8.30 mm (0.3268 in.)

      If the diameter is less than the minimum, replace the bolt.

  88. INSPECT CRANKSHAFT


    1. Inspect for circle runout.


      1. Place the crankshaft on V-blocks.

      2. A01BANYE01

        Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.06 mm (0.0024 in.)

        If the circle runout is greater than the maximum, replace the crankshaft.

    2. Inspect the main journals and crank pins.


      1. A01BGNI

        Using a micrometer, measure the diameter of each main journal and crank pin.

        Main journal diameter
        Size Diameter
        STD 69.982 to 70.000 mm (2.7552 to 2.7559 in.)
        U/S 0.25 69.745 to 69.755 mm (2.7459 to 2.7463 in.)
        U/S 0.50 69.495 to 69.505 mm (2.7360 to 2.7364 in.)
        Crank pin diameter
        Size Diameter
        STD 58.982 to 59.000 mm (2.3221 to 2.3228 in.)
        U/S 0.25 58.745 to 58.755 mm (2.3128 to 2.3132 in.)
        U/S 0.50 58.495 to 58.505 mm (2.3029 to 2.3033 in.)

        If the diameter is not as specified, check the oil clearance (see steps 68 and 74). If necessary, grind or replace the crankshaft.

      2. Check each main journal and crank pin for taper and out-of-round as shown.

        Maximum taper and out-of-round
        0.02 mm (0.0008 in.)

        If the taper and out-of-round is greater than the maximum, replace the crankshaft.

    3. If necessary, grind and hone the main journals and/or crank pins.


      1. Grind and hone the main journals and/or crank pins to the finished undersized diameter (see procedure (b) above).

      2. Install new main journal and/or crankshaft pin undersized bearing.

  89. INSPECT CRANKSHAFT BEARING CAP BOLT


    1. A01BHK9E03

      Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point (A).

      Standard diameter
      13.500 to 14.000 mm (0.5315 to 0.5512 in.)
      Minimum diameter
      12.60 mm (0.4961 in.)

      If the diameter is less than the minimum, replace the bolt