Part 2

ENGINE UNIT DISASSEMBLY Continued

34. CAMSHAFT TIMING TUBE ASSEMBLY
a. Mount the hexagon head portion of the camshaft in a vise.

NOTICE:
^ Be careful not to damage the camshaft.
^ Do not remove the 4 bolts shown in the illustration. The bolts determine the backlash of the gear in the timing tube. If any of the bolts are removed, install a new timing tube assembly.

b. Remove the screw plug and seal washer.
c. Using a 10 mm hexagon wrench, remove the bolt.
d. Pullout the timing tube and drive gear from the camshaft.

e. Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
SST 09960-10010 (09962-01000, 09963-00500)

NOTICE: Be careful not to damage the timing tube.

35. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the RH and LH drain unions.

36. REMOVE WATER SEAL PLATE
a. Remove the 2 nuts.
b. Pry out the seal plate.

37. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.290 mm (0.0063 to 0.0138 inch) maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
Connecting rod thickness: 22.880 to 22.920 mm (0.9008 to 0.9024 inch)

38. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.

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

HINT: Keep the lower bearing inserted with the connecting rod cap.

d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.

f. Lay a strip of Plastigage across the crank pin.

g. Install the connecting rod cap with the 2 bolts.
h. Remove the 2 bolts, connecting rod cap and lower bearing.

i. Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 inch)
Maximum oil clearance: 0.065 mm (0.0026 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, and then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.

Standard Bearings:

EXAMPLE: Connecting rod cap 3 + Crankshaft 1 = "4" (Use bearing 4)

Connecting Rod Big End Inside Diameter:

Crankshaft Crank Pin Diameter:

Standard Sized Bearing Center Wall Thickness (part 1):

Standard Sized Bearing Center Wall Thickness (part 2):

j. Completely remove the Plastigage.

39. INSPECT CRANKSHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 inch)

40. INSPECT CRANKSHAFT OIL CLEARANCE
a. Remove the 10 crankshaft bearing cap bolts.

b. Uniformly loosen and remove the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.

c. Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 crankshaft bearing cap only).

NOTICE: Be careful not to damage the cylinder block.

HINT:
^ Keep the lower bearing and cap together.
^ Be sure to arrange the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

d. Lift out the crankshaft.
e. Remove the 2 upper thrust washers.

HINT:
^ Be sure to arrange the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
^ Keep the upper bearings together with the cylinder block.

f. Clean each crankshaft journal and bearing.
g. Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

h. Install the 10 crankshaft bearings and 5 crankshaft bearing caps with the 30 bolts. Do not install the crankshaft.

i. Using a cylinder gauge, measure the inside diameter of the crankshaft bearing.
Bearing inside diameter: 66.986 to 67.000 mm (2.6372 to 2.6378 inch)
j. Measure the diameter of the crankshaft journal.

k. Subtract the crankshaft journal diameter measurement from the crankshaft bearing inside diameter measurement.

Standard Clearance:

Maximum Clearance:

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

HINT: If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer to the table for the appropriate bearing number. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For other position bearings, use bearings marked 1, 2, 3, 4 and 5. A = Cylinder block B = Crankshaft

No. 1, No. 5:

EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing 4 (Upper), "5" (Lower))

Others (part 1):

Others (part 2):

EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing "2" (Upper), "3" (Lower))

Cylinder Block Crankshaft Journal Bore Diameter (A):

Crankshaft Journal Diameter (B):

Standard Bearing Center Wall Thickness (part 1):

Standard Bearing Center Wall Thickness (part 2):

Others:

l. Remove the 30 bolts, 5 crankshaft bearing caps and 5 lower crankshaft bearings.
m. Remove the 5 upper crankshaft bearings from the cylinder block.

HINT: Be sure to arrange the bearing caps, bearings and thrust washers in such a way that they can be reinstalled exactly as before.

41. REMOVE PISTON AND CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:
^ Keep the bearings, connecting rod and cap together.
^ Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

42. REMOVE WITH PIN PISTON SUB-ASSEMBLY
a. Check the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin with a new piston and pin set.

b. Using a piston ring expander, remove the No.1 and No.2 piston rings.

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

c. Remove the 2 side rails and expander by hand.

d. Using a small screwdriver, pry out the 2 snap rings.

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

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

HINT:
^ The piston and pin are a matched set.
^ Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.