ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A003EWIE01

      Remove the oil filler cap sub-assembly.

  2. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A003GFO

      Remove the ventilation valve sub-assembly.

  3. REMOVE CAM POSITION SENSOR


    1. A003GHME01

      Remove the bolt and camshaft position sensor.

  4. REMOVE CRANK POSITION SENSOR


    1. A003FG7

      Remove the bolt and crank position sensor.

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A003FFIE01

      Remove the bolt and camshaft timing oil control valve.

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003CU7

      Remove the 19 bolts, 2 nuts, head cover and 2 gaskets.

  7. REMOVE CRANKSHAFT PULLEY


    1. A003IDTE04

      Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.

    2. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the bearing cap No.1, as shown in the illustration.

    3. A003C9BE01

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A003GABE01

      Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

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

  8. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove the oil pan drain plug and gasket.

    2. A003EDG

      Remove the 18 bolts and 2 nuts.

    3. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

      Note

      Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.

  9. REMOVE OIL PAN SUB-ASSEMBLY


    1. A003GAH

      Remove the 16 bolts and 2 nuts.

    2. A003B6ME03
      Text in Illustration
      *a Protective Tape

      Using a screwdriver wrapped in protective tape, remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and oil pan sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. Remove the gasket.

  10. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A003GDA

      Remove the 6 bolts and oil strainer sub-assembly.

  11. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. A003AOAE02
      Text in Illustration
      *A w/o Air Conditioning

      w/ Air Conditioning:

      Remove the 16 bolts and nut shown in the illustration.

    2. w/o Air Conditioning:

      Remove the 18 bolts and nut shown in the illustration.

    3. A003B15E04
      Text in Illustration
      *a Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly, cylinder block sub-assembly and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    4. A003EA5E02

      Remove the 3 O-rings.

    5. A003GM3

      Using a 10 mm socket hexagon wrench, remove the timing chain cover plug.

  12. REMOVE WATER PUMP ASSEMBLY


    1. A003DFX

      Remove the 8 bolts, water pump and gasket.

  13. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A003DN1E07
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip taped, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  14. REMOVE OIL PUMP RELIEF VALVE


    1. A003F98

      Using a 27 mm socket wrench, remove the plug and gasket.

    2. Remove the valve spring and relief valve.

  15. REMOVE TIMING CHAIN GUIDE


    1. A003D6PE01

      Remove the 2 bolts, timing chain guide and O-ring.

  16. REMOVE CHAIN TENSIONER ASSEMBLY NO.1

    Note


    • When the chain tensioner is removed, do not rotate the crankshaft.

    • When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90 degrees to the right.


    1. A003DI2E01

      Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. A003D04

      Remove the bolt, nut, chain tensioner assembly No.1 and gasket.

  17. REMOVE CHAIN TENSIONER SLIPPER


    1. A003AYWE01

      Remove the bolt and tensioner slipper.

  18. REMOVE CHAIN VIBRATION DAMPER NO.1


    1. A003F9CE01

      Remove the bolt, nut, and vibration damper.

  19. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain.

  20. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A003ARW

      Remove the crankshaft timing gear from the crankshaft.

  21. REMOVE CAMSHAFT BEARING CAP


    1. A003D7CE01

      Uniformly loosen and remove the 21 bearing cap bolts and 20 washers on the camshafts in the sequence shown in the illustration.

    2. A003D9QE01

      Remove the oil delivery pipe and O-ring from the bearing caps.

    3. A003BKHE01

      Remove the 9 bearing caps.

  22. REMOVE CAMSHAFT


    1. A003H3V

      Remove the camshaft sub-assembly.

  23. REMOVE NO.2 CAMSHAFT


    1. A003H5G

      Remove the No.2 camshaft sub-assembly.

  24. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY NO.1


    1. A003GETE01

      Remove the 16 valve rocker arm sub-assemblies.

  25. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET


    1. A003D1JE01
      Text in Illustration
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the No. 2 camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. Remove the sprocket bolt and camshaft timing sprocket.

  26. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A003BKYE01
      Text in Illustration
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. A003BJIE01

      Check the lock of the camshaft timing gear.


      1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

        Note

        Do not damage the camshaft.

    3. Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

      2. Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.

      3. A003E1YE01

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths.

        CAUTION:

        Some oil splashing will occur. Cover the paths with a shop rag or piece of cloth.

      4. A003EUIE01

        Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.

        OK
        Gear rotates in the advance direction.

        Tech Tips

        This operation releases the lock pin for the most retarded position.

      5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    4. Check for smooth rotation.


      1. Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.

        OK
        Gear rotates in the advance direction.

        CAUTION:

        Do not use air pressure to perform the smooth operation check.

    5. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear is locked at the most retarded position.

  27. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A003BKYE01
      Text in Illustration
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. A003HBOE02

      Remove the fringe bolt and camshaft timing gear.

      Note


      • Do not remove the other 3 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  28. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A003CIVE03

      Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Note


      • Do not drop washers into the cylinder head.

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

    2. Remove the cylinder head.

  29. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head and gasket.

  30. REMOVE CHAIN VIBRATION DAMPER NO.2


    1. A003HNIE01

      Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. A003DXJE01

      Remove the bolt and chain vibration damper No.2.

  31. REMOVE CHAIN VIBRATION DAMPER NO.3


    1. A003I36E01

      Remove the 2 bolts and chain vibration damper No.3.

  32. REMOVE CHAIN TENSIONER ASSEMBLY NO.2


    1. A003HKOE01

      Remove the hexagon wrench from the tensioner assembly

    2. Remove the nut and chain tensioner assembly No.2.

  33. REMOVE NO.2 CHAIN SUB-ASSEMBLY


    1. A003EZ2

      Remove the bolt, balanceshaft drive gear shaft and balanceshaft drive gear.

    2. Remove the crankshaft timing sprocket No.2 and chain.

  34. REMOVE CHAIN VIBRATION DAMPER NO.4


    1. A003BDYE01

      Remove the 2 bolts and vibration damper No.4.

  35. REMOVE CRANKSHAFT PULLEY SET KEY


    1. A003F78

      Remove the 2 pulley set keys from the crankshaft.

  36. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A003BEDE01

      Using SST, remove the oil filter.

      SST
      09228-06501
    2. A003DZBE01

      Using a 27 mm socket wrench, remove the oil filter union.

  37. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A003EWTE01

      Remove the 2 bolts and nut from the oil filter bracket.

    2. Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.

    3. A003I0XE01

      Remove the oil filter bracket gasket and O-ring.

    4. A003F68E01

      Using a hexagon wrench, remove the oil filter bracket union.

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


    1. A003HR4E01

      Remove the taper screw plug from the cylinder block.

  39. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A003EVJE01

      Remove the 6 bolts.

    2. Using a screwdriver with its tip taped, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  40. REMOVE ENGINE REAR OIL SEAL


    1. A003AQ2E01

      Place the oil seal retainer on wooden blocks.

    2. Using a screwdriver with its tip taped and a hammer, tap out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  41. INSPECT CHAIN SUB-ASSEMBLY


    1. A003DJLE01

      Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

    2. Using vernier calipers, measure the length of 16 links.

      Maximum chain elongation
      147.5 mm (5.807 in.)

      If the elongation is greater than the maximum, replace the chain.

      Note

      Perform the same measurement by pulling at random in 3 or more places to obtain an average.

  42. INSPECT NO.2 CHAIN SUB-ASSEMBLY


    1. A003DJLE01

      Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

    2. Using vernier calipers, measure the length of 16 links.

      Maximum chain elongation
      123.6 mm (4.866 in.)

      If the elongation is greater than the maximum, replace the chain.

      Note

      Perform the same measurement by pulling at random in 3 or more places to obtain an average.

  43. INSPECT CHAIN TENSIONER ASSEMBLY NO.1


    1. A003AUSE01

      Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.

  44. INSPECT CHAIN TENSIONER ASSEMBLY NO.2


    1. A003FQ0E01

      Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.

  45. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET


    1. A003HM6E01

      Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.039 in.)

      If the distance is less than the minimum, replace the sprocket.

      If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

    2. Wrap the chain around the sprocket.

    3. Using vernier calipers, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (w/ chain)
      113.8 mm (4.480 in.)

      Tech Tips

      The vernier calipers must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  46. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A003H8LE01

      Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.039 in.)

      If the distance is less than the minimum, replace the timing gear.

      If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

    2. Wrap the chain around the timing gear.

    3. Using vernier calipers, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (w/ chain)
      113.8 mm (4.480 in.)

      Tech Tips

      The vernier calipers must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and timing gear.

  47. INSPECT CRANKSHAFT TIMING GEAR


    1. A003H2NE02

      Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.039 in.)

      If the distance is less than the minimum, replace the sprocket.

      If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

    2. Wrap the chain around the drive sprocket.

    3. Using vernier calipers, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (w/ chain)
      59.4 mm (2.338 in.)

      Tech Tips

      The vernier calipers must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  48. INSPECT CHAIN TENSIONER SLIPPER


    1. A003IELE01

      Using vernier calipers, measure the tensioner slipper wear.

      Maximum wear
      2.0 mm (0.079 in.)

      If the wear is greater than the maximum, replace the tensioner slipper

  49. INSPECT CHAIN VIBRATION DAMPER NO.1


    1. A003ICCE01

      Using vernier calipers, measure the vibration damper wear.

      Maximum wear
      2.0 mm (0.079 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  50. INSPECT TIMING CHAIN GUIDE


    1. A003AUYE01

      Using vernier calipers, measure the chain guide wear.

      Maximum wear
      0.5 mm (0.020 in.)

      If the wear is greater than the maximum, replace the timing chain guide.

  51. INSPECT CRANKSHAFT TIMING SPROCKET NO.2


    1. Wrap the chain around the sprocket.

    2. A003H4I

      Using vernier calipers, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (w/ chain)
      96.7 mm (3.807 in.)

      Tech Tips

      The vernier calipers must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  52. INSPECT BALANCESHAFT DRIVE GEAR SUB-ASSEMBLY


    1. Wrap the chain around the sprocket.

    2. A003DWK

      Using vernier calipers, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (w/ chain)
      75.9 mm (2.988 in.)

      Tech Tips

      The vernier calipers must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  53. INSPECT CHAIN VIBRATION DAMPER NO.2


    1. A003BMTE01

      Using vernier calipers, measure the vibration damper No.2 wear.

      Maximum wear
      1.0 mm (0.039 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  54. INSPECT CHAIN VIBRATION DAMPER NO.3


    1. A003CK3E01

      Using vernier calipers, measure the vibration damper No.3 wear.

      Maximum wear
      1.0 mm (0.039 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  55. INSPECT CHAIN VIBRATION DAMPER NO.4


    1. A003BGFE01

      Using vernier calipers, measure the vibration damper No.4 wear.

      Maximum wear
      1.0 mm (0.039 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  56. INSPECT CYLINDER HEAD SET BOLT


    1. A003HW6E01

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

      Standard outside diameter
      10.76 to 10.97 mm (0.4236 to 0.4319 in.)
      Minimum outside diameter
      10.40 mm (0.4094 in.)

      If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.

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

  57. REMOVE VALVE STEM CAP


    1. A003B0O

      Remove the valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  58. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A003AUQ

      Remove the valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  59. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free from dirt and foreign objects.

    • Only use clean engine oil.


    1. A003COME02

      Place the lash adjuster into a container full of engine oil.

    2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.

      SST
      09276-75010

    3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

    5. After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the lash adjuster.

  60. REMOVE INTAKE VALVE


    1. A003CXTE01

      Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.

      SST
      09202-70020
      09202-00021

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

      Tech Tips

      Arrange the removed parts in the correct order.

  61. REMOVE EXHAUST VALVE


    1. A003I6HE01

      Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.

      SST
      09202-70020
      09202-00021

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

      Tech Tips

      Arrange the removed parts in the correct order.

  62. REMOVE VALVE STEM OIL SEAL


    1. A003H9O

      Using needle-nose pliers, remove the oil seals.

  63. REMOVE VALVE SPRING SEAT


    1. Remove the valve spring seats from the cylinder head.

  64. REMOVE OIL CONTROL VALVE FILTER


    1. A003GC3

      Using an 8 mm hexagon wrench, remove the screw plug.

    2. Remove the oil control valve filter and gasket.

  65. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1


    1. A003FNS

      Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets.

      Note

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

  66. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2


    1. A003DT5

      Using a 19 mm hexagon wrench, remove the screw plug and gasket.

      Note

      If water leaks from the w/ head straight screw plug No.2 or the plug corrodes, replace it.

  67. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A003D2DE01

      Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.

      Maximum warpage
      0.05 mm (0.0020 in.)

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

    2. A003I9L

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

      If cracked, replace the cylinder head.

  68. INSPECT INTAKE VALVE SEATS


    1. A003B48E01

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

    2. Lightly press the valve face against the valve seat.

    3. Check the valve face and valve seat by using the following procedure.


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

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

      3. Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.).

  69. INSPECT EXHAUST VALVE SEATS


    1. A003FQOE01

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

    2. Lightly press the valve face against the valve seat.

    3. Check the valve face and valve seat by using the following procedure.


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

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

      3. Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.).

  70. REPAIR INTAKE VALVE SEATS

    Note

    Keep the lip free from foreign matter.


    1. A003DVJE04

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

    2. A003BHPE02

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

    3. Handrub the valve and valve seat with an abrasive compound.

    4. Check the valve seating position.

  71. REPAIR EXHAUST VALVE SEATS

    Note

    Keep the lip free from foreign matter.


    1. A003BAYE03

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

    2. A003EPHE02

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

    3. Handrub the valve and valve seat with an abrasive compound.

    4. Check the valve seating position.

  72. INSPECT CAMSHAFT


    1. A003H47

      Check the camshaft for runout.


      1. Place the camshaft on V-blocks.

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

        Maximum circle runout
        0.03 mm (0.0012 in.)

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

    2. A003AFF

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      42.855 to 42.955 mm (1.6872 to 1.6911 in.)
      Minimum cam lobe height
      42.855 mm (1.6872 in.)

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

    3. A003EQ6

      Using a micrometer, measure the journal diameter.

      Standard journal diameter
      Journal Diameter
      No.1 journal 35.949 to 35.965 mm (1.4153 to 1.4159 in.)
      Other journal 26.959 to 26.975 mm (1.0614 to 1.0620 in.)

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

  73. INSPECT NO. 2 CAMSHAFT


    1. A003GW9

      Check the camshaft for runout.


      1. Place the camshaft on V-blocks.

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

        Maximum circle runout
        0.03 mm (0.0012 in.)

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

    2. A003GMD

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      42.854 to 42.954 mm (1.687 to 1.6911 in.)
      Minimum cam lobe height
      42.854 mm (1.6872 in.)

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

    3. A003EFE

      Using a micrometer, measure the journal diameter.

      Standard journal diameter
      Journal Diameter
      No.1 journal 35.949 to 35.965 mm (1.4153 to 1.4159 in.)
      Other journal 26.959 to 26.975 mm (1.0614 to 1.0620 in.)

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

  74. INSPECT CAMSHAFT THRUST CLEARANCE


    1. A003BVV

      Install the camshafts (See reassembly, step 49).

      Standard thrust clearance
      0.10 to 0.24 mm (0.004 to 0.009 in.)
      Maximum thrust clearance
      0.26 mm (0.010 in.)

      If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

  75. INSPECT CAMSHAFT OIL CLEARANCE


    1. Clean the bearing caps and camshaft journals.

    2. Place the camshafts on the cylinder head.

    3. A003C8PE01

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

    4. Install the bearing caps (See reassembly, step 49).

      Torque:
      16 N*m  { 160 kgf*cm, 11 ft.*lbf }

      Note

      Do not turn the camshaft.

    5. Remove the bearing caps (See step 21).

    6. A003HGEE01

      Measure the Plastigage at its widest point.

      Standard journal diameter
      Journal Diameter
      No.1 journal 0.035 to 0.072mm (0.0014 to 0.0029 in.)
      Other journal 0.025 to 0.062mm (0.0010 to 0.0024 in.)
      Maximum oil clearance
      0.08 mm (0.003 in.)

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

    7. Completely remove the Plastigage.

  76. INSPECT INNER COMPRESSION SPRING


    1. A003EP1

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

      Free length
      52.13 mm (2.05 in.)

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

    2. A003F8FE02

      Using a steel square, measure the deviation of the inner compression spring at the position shown in the illustration.

      Maximum deviation
      1.3 mm (0.0512 in.)
      Maximum angle (reference)
      2°

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

  77. INSPECT INTAKE VALVE


    1. A003HFOE01

      Using vernier calipers, measure the valve's overall length.

      Standard overall length
      106.26 mm (4.1835 in.)
      Minimum overall length
      105.96 mm (4.1716 in.)

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

    2. A003FGZ

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

      Valve stem diameter
      5.470 to 5.485 mm (0.2154 to 0.2159 in.)
    3. A003C9LE03

      Using vernier calipers, measure the valve head margin thickness.

      Standard margin thickness
      1.05 to 1.45 mm (0.0413 to 0.0571 in.)
      Minimum margin thickness
      0.50 mm (0.0197 in.)

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

  78. INSPECT EXHAUST VALVE


    1. A003DSPE01

      Using vernier calipers, measure the valve's overall length.

      Standard overall length
      106.74 mm (4.2024 in.)
      Minimum overall length
      106.44 mm (4.1905 in.)

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

    2. A003BUR

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

      Valve stem diameter
      5.465 to 5.480 mm (0.2151 to 0.2157 in.)
    3. A003I4WE01

      Using vernier calipers, measure the valve head margin thickness.

      Standard margin thickness
      1.2 to 1.6 mm (0.0472 to 0.0630 in.)
      Minimum margin thickness
      0.50 mm (0.0197 in.)

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

  79. INSPECT VALVE GUIDE BUSHING


    1. A003G6W

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

      Bush inside diameter
      5.510 to 5.530 mm (0.2169 to 0.2177 in.)

    2. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

      Standard oil clearance
      0.025 to 0.060 mm (0.0010 to 0.0024 in.) (Intake)
      0.030 to 0.065 mm (0.0012 to 0.0026 in.) (Exhaust)
      Maximum oil clearance
      0.08 mm (0.0032 in.) (Intake)
      0.10 mm (0.0039 in.) (Exhaust)

      If the clearance is greater than the maximum, replace the intake valve and intake guide bush (See disassembly, step 80 and reassembly, step 19).

      If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush (See disassembly, step 81 and reassembly, step 19).

  80. REMOVE INTAKE VALVE GUIDE BUSH


    1. A003I89E06

      Heat the cylinder head to 80 to 100°C (176 to 212°F)

    2. Place the cylinder head on wooden blocks.

    3. A003HXVE01

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

  81. REMOVE EXHAUST VALVE GUIDE BUSH


    1. Heat the cylinder head to 80 to 100°C (176 to 212 °F).

    2. Place the cylinder head on wooden blocks.

    3. A003GMYE01

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

  82. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A003GDB

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

      Standard thrust clearance
      0.150 to 0.350mm (0.0059 to 0.0138 in.)
      Maximum thrust clearance
      0.40 mm (0.016 in.)

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

  83. INSPECT CONNECTING ROD OIL CLEARANCE


    1. Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

      Tech Tips

      The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

    2. A003FJL

      Remove the 2 connecting rod cap bolts.

    3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

    4. Clean the crank pin and bearing.

    5. Check the crank pin and bearing for pitting and scratches.

    6. A003EEGE01

      Lay a strip of Plastigage on the crank pin.

    7. A003GT9E01

      Check that the front mark of the connecting rod cap is facing forward.

    8. Install the connecting rod cap (See reassembly, step 17).

      Note

      Do not turn the crankshaft.

    9. A003D8H

      Remove the 2 bolts and connecting rod cap (See step (b) and (c) above).

    10. A003DGCE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.039 to 0.066 mm (0.0015 to 0.0026 in.)
      Maximum oil clearance
      0.066 mm (0.0026 in.)

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

      If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 4, 5 or 6 mark on its surface.

      Standard crankshaft pin diameter
      52.989 to 53.002 mm (2.0862 to 2.0867 in.)
      Standard bearing center wall thickness
      Mark Thickness
      4 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
      5 1.488 to 1.490 mm (0.0586 to 0.0587 in.)
      6 1.491 to 1.493 mm (0.0587 to 0.0588 in.)

    11. Completely remove the Plastigage.

  84. REMOVE PISTON SUB-ASSEMBLY W/CONNECTING ROD


    1. A003FNAE01

      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 bearing, connecting rod and cap together.

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

  85. REMOVE CONNECTING ROD BEARING

    Tech Tips

    Arrange the removed parts in the correct order.

  86. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A003F6J

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

      Standard thrust clearance
      0.020 to 0.220 mm (0.0008 to 0.0087 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. If necessary, replace the crankshaft.

      Thrust Washer thickness
      2.440 to 2.490 mm (0.0961 to 0.0980 in.)

  87. REMOVE CRANKSHAFT


    1. A003GV0E01

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

      Tech Tips


      • Keep the lower bearings and crankshaft bearing caps together.

      • Arrange the thrust washers in the correct order.

    2. Lift out the crankshaft.

    3. A003GHQ

      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.

  88. REMOVE CRANKSHAFT BEARING

    Tech Tips

    Arrange the removed parts in the correct order.

  89. REMOVE PISTON RING SET


    1. A003AR1

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

    2. Using a piston ring expander, remove the oil ring rail.

    3. Remove the oil ring expander by hand.

      Tech Tips

      Arrange the piston rings in the correct order.

  90. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A003GFIE01

      Remove the water drain cock sub-assembly from the cylinder block.

    2. Remove the water drain cock plug from the water drain cock sub-assembly.

  91. REMOVE W/PIN PISTON SUB-ASSEMBLY


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


      1. A003D66

        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. Disconnect the connecting rod from the piston.


      1. A003BKVE02

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

      2. A003E02E02

        Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

      3. A003FM4

        Using a brass bar and plastic hammer, 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.

  92. CLEAN W/PIN PISTON SUB-ASSEMBLY


    1. A003BZ6

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

    2. A003EN2

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

    3. A003B5R

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  93. REMOVE OIL NOZZLE NO.1 SUB-ASSEMBLY


    1. A003DACE01

      Using a 5 mm hexagon wrench, remove the oil nozzles.

  94. INSPECT OIL NOZZLE NO.1 SUB-ASSEMBLY


    1. Check the oil nozzles for damage or clogging.

      If necessary, replace the oil nozzle.

  95. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A003HRP

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

      Standard thrust clearance
      0.07 to 0.13 mm (0.0027 to 0.0051 in.)
      Maximum thrust clearance
      0.20 mm (0.0079 in.)

      If the thrust clearance is greater than the maximum, replace the balanceshaft thrust washer. If necessary, replace the balanceshaft.

  96. REMOVE NO.1 BALANCESHAFT


    1. A003ENH

      Remove the bolt.

    2. A003BL6

      Remove the balanceshaft from the cylinder block.

      Note

      When removing the balanceshaft, make sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block side.

  97. REMOVE BALANCESHAFT DRIVEN GEAR NO.1


    1. Mount the head portion of the balanceshaft in a vise.

      Note

      Do not damage the balanceshaft.

    2. Remove the bolt.

    3. A003G4ME02

      Remove the balanceshaft driven gear No.1 (● 1), sliding key (● 2), balanceshaft thrust washer (● 3) and balanceshaft thrust spacer (● 4).

  98. REMOVE NO.2 BALANCESHAFT


    1. A003HQG

      Remove the 2 bolts.

    2. A003F0T

      Remove the balanceshaft from the cylinder block.

      Note

      When removing the balanceshaft, make sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block side.

  99. REMOVE BALANCESHAFT DRIVEN GEAR NO.2


    1. Mount the head portion of the balanceshaft in a vise.

      Note

      Do not damage the balanceshaft.

    2. A003FYWE02

      Remove the bolt.

    3. Remove the balanceshaft driven gear No.2 (● 1) and balanceshaft thrust washer No.2 (● 2).

  100. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A003B9A

      Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

      Maximum warpage
      0.05 mm (0.0020 in.)

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

    2. A003DIK

      Visually check the cylinder for vertical scratches.

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

  101. INSPECT CYLINDER BORE


    1. A003GIUE01

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

      Standard diameter
      94.990 to 95.003 mm (3.7398 to 3.7403 in.)
      Maximum difference diameter
      0.2 mm (0.008 in.)

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

    2. A003FNAE01

      Inspect 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.

  102. CLEAN CYLINDER BLOCK


    1. A003AT0

      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.

  103. INSPECT PISTON DIAMETER


    1. A003FENE02

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

      Distance
      13.8 mm (0.543 in.)
      Piston diameter
      Diameter
      Standard 94.940 to 94.950 mm (3.7378 to 3.7382 in.)

  104. INSPECT PISTON OIL CLEARANCE


    1. Measure the cylinder bore diameter in the thrust direction (See step 101).

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

      Standard oil clearance
      0.019 to 0.052 mm (0.0007 to 0.0020 in.)

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

      Tech Tips


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

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

    3. If the oil clearance is greater than the standard:


      1. Prepare 4 new O/S pistons.

        O/S 0.50 piston diameter
        95.440 to 95.450 mm (3.7575 to 3.7579 in.)

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

        Distance
        13.8 mm (0.543 in.)

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

        Size to be rebored = P + C - H
        P Piston diameter
        C Piston clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 in.)
        H Allowance for honing: 0.02 mm (0.0008 in.) or less

      4. Bore and hone the cylinders to calculated dimensions.

        Maximum honing
        0.02 mm (0.0008 in.)

        Note

        Excess honing will destroy the finished roundness.

  105. INSPECT RING GROOVE CLEARANCE


    1. A003I82

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

      Ring groove clearance
      Ring Clearance
      No. 1 0.020 to 0.075 mm (0.0008 to 0.0030 in.)
      No. 2 0.020 to 0.065 mm (0.0008 to 0.0026 in.)
      Oil 0.020 to 0.070 mm (0.0008 to 0.0028 in.)

      If the clearance is not as specified, replace the piston.

  106. INSPECT PISTON RING END GAP


    1. Insert the piston ring into the cylinder bore.

    2. A003HQQE04

      Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.

    3. A003H2D

      Using a feeler gauge, measure the end gap.

      Standard end gap
      Ring End gap
      No. 1 0.22 to 0.34 mm (0.0087 to 0.0134 in.)
      No. 2 0.45 to 0.57 mm (0.0177 to 0.0224 in.)
      Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
      Maximum end gap
      Ring End gap
      No. 1 0.90 mm (0.0354 in.)
      No. 2 1.36 mm (0.0535 in.)
      Oil 0.75 mm (0.0295 in.)

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

  107. INSPECT PISTON PIN OIL CLEARANCE

    Tech Tips

    There is only 1 type of supply part for piston with pin sub-assembly.


    1. A003BT0

      Using a caliper gauge, measure the inside diameter of the piston pin hole.

      Piston pin hole inside diameter
      22.001 to 22.010 mm (0.8662 to 0.8665 in.)
    2. A003DDZE01

      Using a micrometer, measure the piston pin diameter.

      Piston pin diameter
      21.997 to 22.009 mm (0.8660 to 0.8665 in.)
    3. A003EPZ

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

      Bushing inside diameter
      22.005 to 22.014 mm (0.8663 to 0.8667 in.)

    4. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.

      Standard oil clearance
      0.001 to 0.007 mm (0.00004 to 0.00028 in.)
      Maximum oil clearance
      0.010 mm (0.0004 in.)

      If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

    5. A003FK8E01

      Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

      Standard oil clearance
      0.005 to 0.011 mm (0.0002 to 0.0004 in.)
      Maximum oil clearance
      0.025 mm (0.0010 in.)

    6. If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

  108. INSPECT CONNECTING ROD SUB-ASSEMBLY


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


      1. A003HJH

        Check for bend.

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

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

      2. A003BWW

        Check for twist.

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

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

  109. REMOVE CONNECTING ROD SMALL END BUSH


    1. A003FPC

      Using SST and a press, press out the bush.

      SST
      09222-30010

  110. INSPECT CONNECTING ROD BOLT


    1. A003FT3

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

      Standard diameter
      7.2 to 7.3 mm (0.283 to 0.287 in.)
      Minimum diameter
      7.0 mm (0.276 in.)

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

  111. INSPECT CRANKSHAFT


    1. Inspect for circle runout.


      1. Place the crankshaft on V-blocks.

      2. A003I56E01

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

        Maximum circle runout
        0.03 mm (0.0012 in.)

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

    2. Inspect the main journals.


      1. A003EPGE01
        Text in Illustration
        *a No. 1
        *b No. 2
        *c No. 3
        *d No. 4
        *e No. 5

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

        Standard Journal Diameter (No. 3 Journal)
        59.981 to 59.994 mm (2.36145 to 2.36196 in.)
        Standard Journal Diameter (Other Journal)
        59.987 to 60.000 mm (2.36169 to 2.36220 in.)

        If the diameter is not as specified, check the oil clearance (See step 112). If necessary, replace the crankshaft.

      2. Check each main journal for taper and out-of- round as shown in the illustration.

        Maximum taper and out-of-round
        0.005 mm (0.0002 in.)

        Tech Tips

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

    3. Inspect the crank pin.


      1. A003E6A

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

        Diameter
        52.989 to 53.002 mm (2.0862 to 2.0867 in.)

        If the diameter is not as specified, check the oil clearance (See step 83). If necessary, replace the crankshaft.

      2. Check each crank pin for taper and out-of-round as shown in the illustration.

        Maximum taper and out-of-round
        0.003 mm (0.0001 in.)

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

  112. INSPECT CRANKSHAFT OIL CLEARANCE

    Tech Tips


    • Keep the lower bearings and crankshaft bearing caps together.

    • Arrange the thrust washers in the correct order.

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


    1. Clean each main journal and bearing.

    2. Check each main journal and bearing for pitting and scratches.

      If the journal or bearing is damaged, replace the bearing.

    3. Place the crankshaft on the cylinder block.

    4. A003EB1E01

      Lay a strip of Plastigage across each journal.

    5. A003FW8

      Install the 5 crankshaft bearing caps in their proper locations.

    6. Install the 5 crankshaft bearing caps with the 10 bolts (See reassembly, step 15).

      Note

      Do not turn the crankshaft.

    7. Remove the 10 bolts and 5 crankshaft bearing caps (See step 87).

    8. Measure the Plastigage at its widest point.

      A003B6NE01
      Text in Illustration
      *a Plastigage *b No. 1 Journal
      *c No. 2 Journal *d No. 3 Journal
      *e No. 4 Journal *f No. 5 Journal
      *g Crankshaft Bearing Code *h Cylinder Block Journal Code
      *i Crankshaft Journal Code *j #1J, #2J, #4J, #5J
      *k #3J *l Bearing Code Chart
      Standard oil clearance
      Bearing Cap Standard
      No. 3 0.030 to 0.044 mm (0.00118 to 0.00173 in.)
      Others 0.024 to 0.038 mm (0.000945 to 0.00150 in.)
      Maximum oil clearance
      0.10 mm (0.00394 in.)

      • If the oil clearance is more than the maximum, replace the crankshaft bearing.

      • If replacing the cylinder block, measure the bearing standard clearance.

      • Check the cylinder block journal code and crankshaft journal code and refer to the crankshaft bearing selection chart to select a bearing size.

      • (Example) (Excluding No. 3 journal): When the cylinder block journal code is "D" and the crankshaft journal code is "4", select crankshaft bearing selection code "3" from the crankshaft bearing selection chart.

      Cylinder Block Main Journal Bore Diameter
      Item Specified Condition
      Mark A 64.004 to 64.006 mm (2.51984 to 2.51992 in.)
      Mark B 64.007 to 64.008 mm (2.51996 to 2.51999 in.)
      Mark C 64.007 to 64.008 mm (2.51996 to 2.51999 in.)
      Mark D 64.011 to 64.012 mm (2.52011 to 2.52015 in.)
      Mark E 64.013 to 64.014 mm (2.52019 to 2.52023 in.)
      Mark F 64.015 to 64.016 mm (2.52027 to 2.52031 in.)
      Mark G 64.017 to 64.018 mm (2.52035 to 2.52039 in.)
      Mark H 64.019 to 64.020 mm (2.52043 to 2.52047 in.)
      Mark J 64.021 to 64.022 mm (2.52051 to 2.52055 in.)
      Crankshaft Journal Bore Diameter
      Item Specified Condition (No. 3 Journal) Specified Condition (Other Journal)
      Mark 0 - 59.999 to 60.000 mm (2.36216 to 2.36220 in.)
      Mark 1 - 59.997 to 59.998 mm (2.36208 to 2.36212 in.)
      Mark 2 - 59.995 to 59.996 mm (2.36200 to 2.36204 in.)
      Mark 3 59.993 to 59.994 mm (2.36192 to 2.36196 in.) 59.993 to 59.994 mm (2.36192 to 2.36196 in.)
      Mark 4 59.991 to 59.992 mm (2.36185 to 2.36189 in.) 59.991 to 59.992 mm (2.36185 to 2.36189 in.)
      Mark 5 59.989 to 59.990 mm (2.36177 to 2.36181 in.) 59.989 to 59.990 mm (2.36177 to 2.36181 in.)
      Mark 6 59.987 to 59.988 mm (2.36169 to 2.36173 in.) 59.987 to 59.988 mm (2.36169 to 2.36173 in.)
      Mark 7 59.985 to 59.986 mm (2.36161 to 2.36165 in.) -
      Mark 8 59.983 to 59.984 mm (2.36153 to 2.36157 in.) -
      Mark 9 59.981 to 59.982 mm (2.36145 to 2.36149 in.) -
      Standard Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 1.987 to 1.990 mm (0.07823 to 0.07835 in.)
      Mark 2 1.991 to 1.993 mm (0.07839 to 0.07846 in.)
      Mark 3 1.994 to 1.996 mm (0.07850 to 0.07858 in.)
      Mark 4 1.997 to 1.999 mm (0.07862 to 0.07870 in.)
      Mark 5 2.000 to 2.002 mm (0.07874 to 0.07882 in.)

    9. Completely remove the Plastigage.

  113. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A003HXO

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

      Standard diameter
      10.76 to 10.97 mm (0.4236 to 0.4319 in.)
      Minimum diameter
      10.66 mm (0.4197 in.)

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

  114. INSPECT NO.1 BALANCESHAFT


    1. Inspect the diameter of the journal.


      1. A003C24E01

        Using a micrometer, measure the diameter of the balanceshaft main journals.

        Main journal diameter
        Journal Diameter
        A 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
        B 37.449 to 37.465 mm (1.4744 to 1.4750 in.)

    2. Inspect the diameter of the bearing.


      1. A003AK9E01

        Using a cylinder gauge, measure the inside diameter of the balanceshaft bearing.

        Bearing inside diameter
        Bearing Diameter
        A 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
        B 37.525 to 37.545 mm (1.4774 to 1.4781 in.)

    3. Inspect oil clearance.


      1. Subtract the balanceshaft main journal diameter measurement from the balanceshaft bearing inside diameter measurement.

        Standard oil clearance
        Clearance
        A 0.040 to 0.076 mm (0.0016 to 0.0030 in.)
        B 0.060 to 0.096 mm (0.0024 to 0.0038 in.)
        Maximum oil clearance:
        0.15 mm (0.0059 in.)

        If the oil clearance is greater than the maximum, replace the cylinder block and balanceshaft.

  115. INSPECT NO.2 BALANCESHAFT


    1. Inspect the diameter of the journal.


      1. A003AMFE01

        Using a micrometer, measure the diameter of the balanceshaft main journals.

        Main journal diameter
        Journal Diameter
        A 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
        B 37.449 to 37.465 mm (1.4744 to 1.4750 in.)

    2. Inspect the diameter of the bearing.


      1. A003AXAE01

        Using a cylinder gauge, measure the inside diameter of the balanceshaft bearing.

        Bearing inside diameter
        Bearing Diameter
        A 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
        B 37.525 to 37.545 mm (1.4774 to 1.4781 in.)

    3. Inspect oil clearance.

      Standard oil clearance
      Clearance
      A 0.040 to 0.076 mm (0.0016 to 0.0030 in.)
      B 0.060 to 0.096 mm (0.0024 to 0.0038 in.)
      Maximum oil clearance
      0.15 mm (0.0059 in.)

      If the oil clearance is greater than the maximum, replace the cylinder block and balanceshaft.