ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 9 bolts, nut, cylinder head cover, and gasket.

  3. REMOVE CAMSHAFT TIMING PULLEY


    1. Set the No.1 cylinder to approx. 90° BTDC/compression.

      Tech Tips

      Set the No.1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.


      1. A003BR0E01

        Using the crankshaft pulley bolt, turn the crankshaft 90°counterclockwise, and put the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

    2. A003HKKE01

      Using SST, loosen the pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    3. A003FALE01

      Using SST, separate the timing pulley from the camshaft.

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

    4. Remove the pulley bolt and timing pulley.

    5. Remove the timing gear woodruff key.

  4. REMOVE TIMING BELT COVER NO.2


    1. Remove the 4 bolts and timing belt cover.

  5. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. Remove the 4 bolts, retainer and gasket.

  6. REMOVE OIL SEAL RETAINER, NO.2 OIL SEAL


    1. A003DIF

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

      Note

      Tape the screwdriver tip.

  7. REMOVE CAMSHAFT


    1. A003BK5E01

      Turn the camshaft with a wrench so that the key groove faces upward.

    2. A003CLKE01

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

    3. Remove the 5 bearing caps and camshaft.

    4. Remove the 10 bearings from the bearing caps and cylinder head.

      Tech Tips

      Arrange the bearings in the correct order.

  8. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A003B08E01

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

      Note

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

    2. A003G2Y

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

      Note

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

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

  9. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder gasket from the cylinder head.

  10. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A003GWBE01

      Remove the 2 bolts (A and B).

    2. Loosen the bolt (C), and remove the timing belt idler No.1.

  11. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2


    1. Remove the bolt, timing belt idler No.2 and spacer.

  12. INSPECT TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A003I6ZE01

      Visually check the seal portion of the timing belt idler No.1 for oil leakage.

      If leakage is found, replace the timing belt idler No.1.

    2. Check that the timing belt idler No.1 turns smoothly.

      If necessary, replace the timing belt idler No.1.

  13. INSPECT TIMING BELT IDLER SUB-ASSEMBLY NO.2


    1. Check that the timing belt idler No.2 turns smoothly.

      If necessary, replace the timing belt idler No.2.

  14. INSPECT IDLER TENSION SPRING


    1. A003BKWE01

      Measure the free length of the tension spring.

      Free length
      44.4 to 45.4 mm (1.748 to 1.787 in.)

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

    2. Measure the tension of the tension spring at the specified installed length.

      Installed tension
      53 to 59 N (5.42 to 5.98 kgf, 11.9 to 13.2 lbf) at 52.1 mm (2.051 in.)

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

  15. REMOVE WATER PUMP ASSEMBLY


    1. Remove the 6 bolts, tension spring bracket, water pump and gasket.

  16. REMOVE CRANKSHAFT TIMING PULLEY


    1. A003G74E01

      If the timing pulley cannot be removed by a screwdriver, remove it with SST.

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

  17. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 16 bolts and 2 nuts.

    2. A003BSSE04

      Insert the blade of a oil pan seal cutter between the oil pan and cylinder block, and cut off applied sealer and remove the oil pan.

      Note


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

      • Do not damage the oil pan flange.

  18. REMOVE OIL STRAINER SUB-ASSEMBLY


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

  19. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. Remove the 5 bolts, timing gear case and gasket.

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


    1. A003F3J

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

      Note

      Tape the screwdriver tip.

  21. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. Remove the 4 bolts, oil seal retainer and gasket.

  22. REMOVE ENGINE REAR OIL SEAL


    1. A003C65

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

      Note

      Tape the screwdriver tip.

  23. INSPECT CYLINDER HEAD SET BOLT


    1. A003FE9E01

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

      Standard outer diameter
      11.80 to 12.00 mm (0.4646 to 0.4724 in.)
      Minimum outer diameter
      11.60 mm (0.4567 in.)

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

  24. REMOVE VALVE LIFTER


    1. Remove the valve lifter and adjusting shim.

      Tech Tips

      Arrange the valve lifters and shims in the correct order.

  25. REMOVE INTAKE VALVE


    1. A003AZTE01

      Using SST, compress the valve spring and remove the 2 retainer locks.

      SST
      09202-70020   ( 09202-00030 )

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

      Tech Tips

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

  26. REMOVE EXHAUST VALVE


    1. A003EIJE01

      Using SST, compress the valve spring and remove the 2 retainer locks.

      SST
      09202-70020   ( 09202-00030 )

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

      Tech Tips

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

  27. REMOVE VALVE STEM OIL SEAL


    1. A003DWU

      Using needle-nose pliers, remove the oil seal.

  28. REMOVE COMBUSTION CHAMBER SUB-ASSEMBLY


    1. A003GBIE01

      Using SST, remove the 4 combustion chambers (and shims).

      SST
      09208-48010

      Tech Tips

      Arrange the combustion chambers (and shims) in the correct order.

  29. CLEAN CYLINDER HEAD SUB-ASSEMBLY


    1. A003CIF

      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. A003E2J

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

      Note

      Do not scratch the cylinder block contact surface.

    3. A003GQW

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

    4. A003ERY

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

  30. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. Inspect for warpage.


      1. A003C7QE02

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

        Maximum warpage
        0.20 mm (0.0079 in.)

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

    2. Inspect for cracks.


      1. A003F29

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

        If cracked, replace the cylinder head.

  31. CLEAN INTAKE VALVE


    1. A003BC2

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

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

  32. INSPECT INTAKE VALVE


    1. A003FOJ

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

      Valve stem diameter
      7.975 to 7.990 mm (0.3140 to 0.3146 in.)
    2. A003DP5E05

      Check the valve face angle.


      1. 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°
    3. A003C3CE03

      Check the valve head margin thickness.

      Standard margin thickness
      1.6 mm (0.063 in.)
      Minimum margin thickness
      1.1 mm (0.043 in.)

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

    4. A003ET1E02

      Check the valve overall length.

      Standard overall length
      104.10 to 104.50 mm (4.0984 to 4.1142 in.)
      Minimum overall length
      103.60 mm (4.0787 in.)

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

    5. A003G56

      Check the surface of the valve stem tip for wear.

      Note

      Do not grind off more than minimum.

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

  33. CLEAN EXHAUST VALVE


    1. A003BC2

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

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

  34. INSPECT EXHAUST VALVE


    1. A003FOJ

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

      Valve stem diameter
      7.960 to 7.975 mm (0.3134 to 0.3140 in.)
    2. A003DP5E05

      Check the valve face angle.


      1. 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°

    3. Check the valve head margin thickness.

      Standard margin thickness
      1.7 mm (0.067 in.)
      Minimum margin thickness
      1.2 mm (0.047 in.)

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

    4. A003ET1E02

      Check the valve overall length.

      Standard overall length
      103.95 to 104.35 mm (4.0925 to 4.1083 in.)
      Minimum overall length
      103.45 mm (4.0728 in.)

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

    5. A003G56

      Check the surface of the valve stem tip for wear.

      Note

      Do not grind off more than minimum.

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

  35. INSPECT INNER COMPRESSION SPRING


    1. A003IDCE01

      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. A003GD4E02

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

      Free length
      Type Length
      Type A 46.20 mm (1.8189 in.)
      Type B 48.54 mm (1.9110 in.)

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

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

      Installed tension
      301 to 322 N (30.7 to 33.9 kgf, 67.7 to 74.7 lbf) at 37.00 mm (1.4567 in.)

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

  36. INSPECT INTAKE VALVE GUIDE BUSH


    1. A003EE3E01

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

      Bush inside diameter
      8.010 to 8.030 mm (0.3154 to 0.3161 in.)

    2. Subtract the valve stem diameter measurement (See step 32) from the guide bush inside diameter measurement.

      Standard oil clearance
      0.020 to 0.055 mm (0.0008 to 0.0022 in.)
      Maximum oil clearance
      0.08 mm (0.0031 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush (See step 38 and 40).

  37. INSPECT EXHAUST VALVE GUIDE BUSH


    1. A003H6LE01

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

      Bush inside diameter
      8.010 to 8.030 mm (0.3154 to 0.3161 in.)

    2. Subtract the valve stem diameter measurement (See step 34) from the guide bush inside diameter measurement.

      Standard oil clearance
      0.035 to 0.070 mm (0.0014 to 0.0028 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush (See step 39 and 41).

  38. REMOVE INTAKE VALVE GUIDE BUSH


    1. A003CTAE01

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

      SST
      09201-10000   ( 09201-01080 )
      09950-70010   ( 09951-07100 )

  39. REMOVE EXHAUST VALVE GUIDE BUSH


    1. A003GB4E01

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

      SST
      09201-10000   ( 09201-01080 )
      09950-70010   ( 09951-07100 )

  40. INSTALL INTAKE VALVE GUIDE BUSH


    1. 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 bore diameter Bush size
      13.004 to 13.025 mm (0.5120 to 0.5128 in.) Use STD
      13.054 to 13.075 mm (0.5139 to 0.5148 in.) Use O/S 0.05

      If the bush bore diameter of the cylinder head is greater than 13.025 mm (0.5128 in.), machine the bush bore to dimension of 13.054 to 13.075 mm (0.5139 to 0.5148 in.).

      If the bush bore diameter of the cylinder head is greater than 13.075 mm (0.5148 in.), replace the cylinder head.

    3. A003BJRE01

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

      SST
      09201-10000   ( 09201-01080 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      10.8 to 11.2 mm (0.425 to 0.441 in.)
    4. A003GVJE01

      Using a sharp 8.0 mm reamer, ream the guide bush to obtain the standard specified clearance (See step 36) between the guide bush and valve stem.

  41. INSTALL EXHAUST VALVE GUIDE BUSH


    1. A003DEF

      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 bore diameter Bush size
      13.004 to 13.025 mm (0.5120 to 0.5128 in.) Use STD
      13.054 to 13.075 mm (0.5139 to 0.5148 in.) Use O/S 0.05

      If the bush bore diameter of the cylinder head is greater than 13.025 mm (0.5128 in.), machine the bush bore to dimension of 13.054 to 13.075 mm (0.5139 to 0.5148 in.).

      If the bush bore diameter of the cylinder head is greater than 13.075 mm (0.5148 in.), replace the cylinder head.

    3. A003I5RE01

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

      SST
      09201-10000   ( 09201-01080 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      10.8 mm to 11.2 mm (0.425 to 0.441 in.)
    4. A003DQSE01

      Using a sharp 8.0 mm reamer, ream the guide bush to obtain the standard specified clearance (See step 37) between the guide bush and valve stem.

  42. INSPECT INTAKE VALVE SEATS


    1. A003F8Q

      Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

    2. A003AQQE01

      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 by using the following procedure:


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

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

      3. Check that the seat contacts in the middle of the valve face with the following width:

        Width
        1.5 to 1.9 mm (0.059 to 0.075 in.)

  43. INSPECT EXHAUST VALVE SEATS


    1. A003AXN

      Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

    2. A003FKWE01

      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 by using the following procedure:


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

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

      3. Check that the seat contacts in the middle of the valve face with the following width:

        Width
        1.8 to 2.2 mm (0.071 to 0.087 in.)

  44. REPAIR INTAKE VALVE SEATS


    1. A003FGHE02

      If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

    2. A003EPQE02

      If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

    3. A003CNZ

      Handrub the valve and valve seat with an abrasive compound.

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

  45. REPAIR EXHAUST VALVE SEATS


    1. A003FGHE03

      If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

    2. A003EPQE03

      If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

    3. A003CN7

      Handrub the valve and valve seat with an abrasive compound.

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

  46. INSPECT VALVE LIFTER


    1. A003DU7

      Using a micrometer, measure the lifter diameter.

      Lifter diameter
      40.892 to 40.902 mm (1.6099 to 1.6103 in.)
    2. A003FIH

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

      Lifter bore diameter
      40.960 to 40.980 mm (1.6126 to 1.6134 in.)

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

      Standard oil clearance
      0.058 to 0.088 mm (0.0023 to 0.0035 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

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

  47. INSPECT CAMSHAFT


    1. Inspect the circle runout.


      1. Place the camshaft on V-blocks.

      2. A003D2N

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

        Maximum circle runout
        0.10 mm (0.0039 in.)

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

    2. Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      Cam lobe height
      Intake 54.890 to 54.910 mm (2.1610 to 2.1618 in.)
      Exhaust 54.990 to 55.010 mm (2.1650 to 2.1657 in.)
      Minimum cam lobe height
      Cam lobe height
      Intake 54.39 mm (2.1413 in.)
      Exhaust 54.49 mm (2.1453 in.)

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

    3. Inspect the journal diameter of the camshaft.


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

        Journal diameter
        Journal Diameter
        STD No.1 34.969 to 34.985 mm (1.3767 to 1.3774 in.)
        Other 27.969 to 27.985 mm (1.1011 to 1.1018 in.)
        U/S 0.125 No.1 34.844 to 34.860 mm (1.3718 to 1.3724 in.)
        Other 27.844 to 27.860 mm (1.0962 to 1.0968 in.)
        U/S 0.250 No.1 34.719 to 34.735 mm (1.3669 to 1.3675 in.)
        Other 27.719 to 27.735 mm (1.0913 to 1.0919 in.)

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

    4. A003GQPE01

      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 them.

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

      4. Place the camshaft on the cylinder head.

      5. Lay a strip of Plastigage across each of the journals.

      6. Install the bearing caps (See reassembly, step 37).

        Note

        Do not turn the camshaft.

      7. Remove the bearing caps (See step 7).

      8. A003CCJE01

        Measure the Plastigage at its widest point.

        Standard oil clearance
        0.022 to 0.074 mm (0.0009 to 0.0029 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 camshaft.

      9. Completely remove the Plastigage.

      10. Remove the camshaft.

    5. If necessary, grind and hone the camshaft journals.


      1. Grind and hone the journals to U/S diameter (See procedure (c) above). Install new journal U/S bearings.

    6. Check the thrust clearance.


      1. Install the camshaft (See reassembly, step 37).

      2. A003E54

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

        Standard thrust clearance
        0.080 to 0.280 mm (0.0031 to 0.0110 in.)
        Maximum thrust clearance
        0.35 mm (0.0138 in.)

        If the thrust clearance is greater than the maximum, replace the No.1 bearing. If necessary, replace the camshaft.

  48. REMOVE SEMICIRCULAR PLUG


    1. Remove the semicircular plug from the cylinder head.

  49. INSPECT CONNECTING ROD THRUST CLEARANCE

    Tech Tips


    • Thoroughly clean all parts to be assembled.

    • Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

    • Replace all gaskets, O-rings and oil seals with new ones.


    1. A003DUU

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

      Standard thrust clearance
      0.080 to 0.300 mm (0.0031 to 0.0118 in.)
      Maximum thrust clearance
      0.35 mm (0.0138 in.)

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

  50. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A003CJDE01

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

    2. Remove the 2 connecting rod cap nuts.

    3. A003HK8

      Using a plastic hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.

      Tech Tips

      Keep the lower bearing inserted with the connecting rod cap.

    4. A003B81

      Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

    5. Clean the crank pin and bearing.

    6. 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.

    7. A003GEQE01

      Lay a strip of Plastigage across the crank pin.

    8. A003FGU

      Install the connecting rod cap with the 2 nuts (See reassembly, step 15).

      Note

      Do not turn the crankshaft.

    9. Remove the 2 nuts, connecting rod cap and lower bearing (See procedure (b) and (c) above).

    10. A003DTSE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Size Oil clearance
      STD 0.036 to 0.064 mm (0.0014 to 0.0025 in.)
      U/S 0.25 U/S 0.50 0.033 to 0.079 mm (0.0013 to 0.0031 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.

    11. A003H6AE01

      If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

      Standard sized bearing center wall thickness
      Mark Center wall thickness
      1 1.478 to 1.482 mm (0.0582 to 0.0583 in.)
      2 1.482 to 1.486 mm (0.0583 to 0.0585 in.)
      3 1.486 to 1.490 mm (0.0585 to 0.0587 in.)

      1. Completely remove the Plastigage.

  51. REMOVE PISTON AND CONNECTING ROD


    1. A003HT8E01

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

    2. A003B81

      Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

    3. 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.

      • Arrange the piston and connecting rod assemblies in the correct order.

  52. REMOVE PISTON SUB-ASSEMBLY W/PIN


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


      1. A003E97

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

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

    2. Remove the piston rings.


      1. A003D3L

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

      2. Remove the oil ring and coil by hand.

        Tech Tips

        Arrange the piston rings in the correct order.

    3. Disconnect the connecting rod from the piston.


      1. A003BKF

        Using snap ring pliers, remove the snap rings.

      2. A003G15E01

        Gradually heat the piston to approx. 60°C (140°F).

      3. A003FZO

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

        Tech Tips


        • The piston and pin are a matched set.

        • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

  53. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A003H1D

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

      Standard thrust clearance
      0.040 to 0.250 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 2.493 to 2.543 mm (0.0981 to 0.1001 in.)
      O/S 0.250 2.555 to 2.605 mm (0.1006 to 0.1026 in.)

  54. INSPECT CRANKSHAFT OIL CLEARANCE


    1. A003AOTE01

      Remove the 10 crankshaft bearing cap bolts.

    2. A003DOR

      Using the removed crankshaft bearing cap bolts, pry the cap back and forth, and remove the crankshaft bearing caps, lower bearings and lower thrust washers (No.3 crankshaft bearing cap only).

      Tech Tips


      • Keep the lower bearing and crankshaft bearing caps together.

      • Arrange the thrust washers in the correct order.

    3. Lift out the crankshaft.

      Tech Tips

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

    4. Clean each main journal and bearing.

    5. 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.

    6. Place the crankshaft on the cylinder block.

    7. A003ER2E01

      Lay a strip of Plastigage across each journal.

    8. A003EVDE01

      Install the 5 crankshaft bearing caps with the 10 bolts (See reassembly, step 14).

      Note

      Do not turn the crankshaft.

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

    10. A003D0XE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Size Oil clearance
      STD 0.034 to 0.065 mm (0.0013 to 0.0026 in.)
      U/S 0.25, U/S 0.50 0.033 to 0.079 mm (0.0013 to 0.0031 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.

    11. A003EHIE01

      If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

      Standard sized bearing center wall thickness
      Mark Center wall thickness
      1 1.979 to 1.983 mm (0.0779 to 0.0781 in.)
      2 1.983 to 1.987 mm (0.0781 to 0.0782 in.)
      3 1.987 to 1.991 mm (0.0782 to 0.0784 in.)

    12. Completely remove the Plastigage.

  55. REMOVE CRANKSHAFT


    1. Lift out the crankshaft.

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

      Tech Tips

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

  56. REMOVE OIL NOZZLE NO.1 SUB-ASSEMBLY


    1. Remove the 4 check valves and oil nozzles.

  57. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A003EQXE01

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

      If stuck, replace the check valve.

  58. INSPECT OIL NOZZLE NO.1 SUB-ASSEMBLY


    1. Check the oil nozzles for damage or clogging.

      If necessary, replace the oil nozzle.

  59. REMOVE CYLINDER BLOCK OIL ORIFICE


    1. Using a 6 mm hexagon wrench, remove the oil orifice.

  60. INSPECT CYLINDER BLOCK OIL ORIFICE


    1. Check the oil orifice for damage or clogging.

      If necessary, replace the oil orifice.

  61. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Remove the water drain cock from the cylinder block.

  62. REMOVE W/HEAD TAPER SCREW PLUG NO.1


    1. Remove the screw plug from the cylinder block.

  63. CLEAN CYLINDER BLOCK SUB-ASSEMBLY


    1. A003D3K

      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.

  64. INSPECT CYLINDER BLOCK SUB-ASSEMBLY


    1. Inspect for warpage.


      1. A003G92

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

        Maximum warpage
        0.20 mm (0.0079 in.)

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

    2. A003COQ

      Visually check the cylinder for vertical scratches.

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

    3. A003DY2E01

      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. A003IESE07

        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 99.500 to 99.510 mm (3.9173 to 3.9177 in.)
        2 99.510 to 99.520 mm (3.9177 to 3.9181 in.)
        3 99.520 to 99.530 mm (3.9181 to 3.9185 in.)
        Maximum diameter
        Diameter
        STD 99.73 mm (3.9264 in.)
        O/S 0.50 100.23 mm (3.9461 in.)

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

    4. A003HT8E01

      Remove the cylinder ridge.

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

  65. CLEAN PISTON SUB-ASSEMBLY W/PIN


    1. A003GW1

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

    2. A003EC1

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

    3. A003CBU

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  66. INSPECT PISTON SUB-ASSEMBLY W/PIN

    Tech Tips


    • When replacing the piston and pin as a set with a supply part, there are a number of piston diameter sizes 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. A003HG1E01

        Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston head is as specified.

        Distance
        61.27 to 61.33 mm (2.4122 to 2.4146 in.)
        Piston diameter
        Size Diameter
        STD Mark 1 99.450 to 99.460 mm (3.9153 to 3.9157 in.)
        STD Mark 2 99.460 to 99.470 mm (3.9157 to 3.9161 in.)
        STD Mark 3 99.470 to 99.480 mm (3.9161 to 3.9165 in.)
        O/S 0.50 99.950 to 99.980 mm (3.9350 to 3.9362 in.)

      2. Measure the cylinder bore diameter in the thrust direction (See step 64).

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

        Standard oil clearance
        0.040 to 0.060 mm (0.0016 to 0.0024 in.)
        Maximum oil clearance
        0.13 mm (0.0051 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.

    2. A003GT1E01

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

    3. Inspect the piston pin fitting condition.


      1. A003DZ3

        Check that the piston pin is pushed into the piston pin hole with your thumb at 60°C (140°F).

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

    4. A003FK9

      Using a micrometer, measure the piston pin diameter.

      Piston pin diameter
      29.000 to 29.012 mm (1.1417 to 1.1422 in.)

  67. INSPECT PISTON RING SET


    1. Inspect the piston ring groove clearance.


      1. A003GUXE01

        No. 1 Ring: Install a new piston ring to the piston. Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove.

        Standard groove clearance
        0.057 to 0.101 mm (0.0022 to 0.0040 in.)
        Maximum groove clearance
        0.20 mm (0.0079 in.)

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

      2. A003D5DE01

        No. 2 and Oil Rings: 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. 2 0.060 to 0.100 mm (0.0024 to 0.0039 in.)
        Oil 0.030 to 0.070 mm (0.0012 to 0.0028 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. A003F3ME01

        Insert the piston ring into the cylinder bore.

      2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 140 mm (5.51 in.) from the top of the cylinder block.

      3. A003C2X

        Using a feeler gauge, measure the end gap.

        Standard end gap
        Ring End gap
        No. 1 0.350 to 0.590 mm (0.0138 to 0.0232 in.)
        No. 2 0.470 to 0.720 mm (0.0185 to 0.0283 in.)
        Oil 0.200 to 0.520 mm (0.0079 to 0.0205 in.)
        Maximum end gap
        Ring End gap
        No. 1 1.29 mm (0.0508 in.)
        No. 2 1.42 mm (0.0559 in.)
        No. 3 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.

  68. INSPECT CONNECTING ROD SUB-ASSEMBLY


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


      1. A003B47

        Check for bend.

        Maximum bend
        0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

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

      2. A003C51

        Check for twist

        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.

  69. INSPECT PISTON PIN OIL CLEARANCE

    Tech Tips

    When replacing the piston and pin as a set with a supply part, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.


    1. Inspect the piston pin oil clearance.


      1. A003FXB

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

        Bush inside diameter
        29.008 to 29.020 mm (1.1420 to 1.1425 in.)

      2. Subtract the piston pin diameter measurement (See step 66) from the bush inside diameter measurement.

        Standard oil clearance
        0.004 to 0.012 mm (0.0002 to 0.0005 in.)
        Maximum oil clearance
        0.05 mm (0.0020 in.)

        If the oil clearance is greater than the maximum, replace the bush.

        If necessary, replace the piston and piston pin as a set.

  70. REMOVE CONNECTING ROD SMALL END BUSH


    1. A003APPE01

      Using SST and a press, press out the bush.

      SST
      09222-54011   ( 09222-03016, 09222-03026 )

  71. INSPECT CONNECTING ROD BOLT


    1. A003AWHE01

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

      Standard diameter
      8.400 to 8.600 mm (0.3307 to 0.3386 in.)
      Minimum diameter
      8.20 mm (0.3228 in.)

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

  72. BORE CYLINDER

    Tech Tips


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

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


    1. A003HG1E01

      Prepare 4 new O/S pistons.

      O/S 0.50 piston diameter
      99.950 to 99.980 mm (3.9350 to 3.9362 in.)

    2. Using a micrometer, measure the piston diameter at right angles to the piston pin center line where the distance from the piston head is as specified.

      Distance
      61.27 to 61.33 mm (2.4122 to 2.4146 in.)

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

      Tech Tips


      • Size to be rebored = P + C - H

      • P = Piston diameter

      • C = Piston clearance: 0.040 to 0.060 mm (0.0016 to 0.0024 in.)

      • H = Allowance for honing: 0.02 mm (0.0008 in.) or less

    4. Bore and hone the cylinders to the calculated dimensions.

      Maximum honing
      0.02 mm (0.0008 in.)

      Note

      Excess honing will destroy the finished roundness.

  73. INSPECT CRANKSHAFT


    1. Inspect for circle runout.


      1. Place the crankshaft on V-blocks.

      2. A003B8E

        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. A003CJV

      Inspect the main journals and crank pins.


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

        Main journal diameter
        Size Diameter
        STD 61.985 to 62.000 mm (2.4403 to 2.4409 in.)
        U/S 0.25 61.745 to 61.755 mm (2.4309 to 2.4313 in.)
        U/S 0.50 61.495 to 61.505 mm (2.4211 to 2.4215 in.)
        Crank pin diameter
        Size Diameter
        STD 54.988 to 55.000 mm (2.1649 to 2.1654 in.)
        U/S 0.25 54.745 to 54.755 mm (2.1553 to 2.1557 in.)
        U/S 0.50 54.495 to 54.505 mm (2.1455 to 2.1459 in.)

        If the diameter is not as specified, check the oil clearance (See steps 50 and 54). 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 in step (b) above).

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