Removal and Installation

DISASSEMBLY
1. Remove rear oil seal retainer.
(a) Remove the 4 bolts.

(b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.
2. Check connecting rod thrust clearance.

Using a dial indicator, measure the thrust clearance while moving the rod back and forth.
Standard thrust clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)
Maximum thrust clearance: 0.45 mm (0.0177 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. Remove connecting rod caps and check oil clearance.

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

(b) Remove the 2 connecting rod cap nuts.

(c) Using a soft-faced hammer, lightly tap the connecting rod bolt and lift the cap and lower bearing.

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

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

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

(g) Lay a strip of Plastigage across the crank pin.

(h) Install the connecting rod cap.
Torque: 40 Nm (400 kg.cm, 29 ft. lbs.)

CAUTION: Do not turn the crankshaft.

(i) Remove the connecting rod cap.
(See procedure (b) and (c) above)

(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD: 0.016 - 0.048 mm (0.0006 - 0.0019 inch)
U/S 0.25: 0.015 - 0.058 mm (0.0006 - 0.0023 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

NOTE: If using a standard bearing, replace with one having the same number as marked on the bearing cap. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

Reference.

(k) Completely remove the Plastigage.
4. Remove piston and connecting rod assemblies.

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

(b) Cover the rod bolts with a short piece of hose to protect the crankshaft from damage.
(c) Push out the piston and connecting rod assembly and the upper bearing though the top of the cylinder block.

NOTE:
^ Keep the bearing, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in correct order.

5. Check crankshaft thrust clearance.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.02 - 0.20 mm (0.0008 - 0.0079 inch)
Maximum thrust clearance: 0.3 mm (0.012 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness:
STD: 2.430 - 2.480 mm (0.0957 - 0.0976 inch)
O/S 0.125: 2.493 - 2.543 mm (0.0981 - 0.1001 inch)
6. Remove main bearing caps and check oil clearance.

(a) Uniformly loosen and remove the 10 main bearing cap bolts, in several passes, in the sequence shown.

(b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the 5 main bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 main bearing cap only).

NOTE:
^ Keep the lower bearing inserted together with cap.
^ Arrange the main bearing caps and lower thrust washers in correct order.

(c) Lift out the crankshaft.

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

(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.

(g) Lay a strip of Plastigage across each journal.

(h) Install the main bearing caps.
Torque: 58 Nm (580 kg.cm, 42 ft. lbs.)

CAUTION: Do not turn the crankshaft.

(i) Remove the main bearing caps.
(See procedure (a) and (b) above)

(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD: 0.016 - 0.035 mm (0.0006 - 0.0014 inch)
U/S 0.25: 0.015 - 0.055 mm (0.0006 - 0.0022 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)

NOTE: If replacing the cylinder block subassembly, the bearing standard clearance will be: 0.018 - 0.045 mm (0.0007 - 0.0018 inch)

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

NOTE: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Example: Cylinder block "2" + crankshaft "1" = Total number 3 (Use bearing "3").

Reference.

(k) Completely remove the Plastigage.

7. Remove crankshaft.
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust washers from the cylinder block.

NOTE: Arrange the main bearings and thrust washers in correct order.

ASSEMBLY

NOTE:
^ 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 parts.

1. Install main bearings.

(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

CAUTION: Install the bearing with the oil hole in the cylinder block.

(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

NOTE: A number is marked on each main bearing cap to indicate the illustration position.

2. Install upper thrust washers.

Install the 2 thrust washers under the No. 3 journal position with the oil grooves facing outward.
3. Place crankshaft on cylinder block.
4. Install main bearing caps and lower thrust washers.

(a) Install the 2 thrust washers on the No. 3 bearing cap with the oil grooves facing outward.

(b) Install the 5 main bearing caps in their proper locations.

NOTE: Each bearing cap has a number and front mark.

(c) Apply a light coat of engine oil on the threads and under the heads of the main bearing caps.

(d) Install and uniformly tighten the 10 bolts of the main bearing caps, in several passes, in the sequence shown.
Torque: 58 Nm (580 kg.cm, 42 ft. lbs.)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance.
5. Install piston and connecting rod assemblies.

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

(b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
6. Install connecting rod caps.
(a) Match the numbered connecting rod cap with the numbered connecting rod.

(b) Install the connecting rod cap with the front mark facing forward.
(c) Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap.

(d) Install and alternately tighten the nuts of the connecting rod cap in several passes.
Torque: 40 Nm (400 kg.cm, 29 ft. lbs.)
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance.
7. Install rear oil seal retainer.
(a) Remove any old packing, Formed In Place Gasket (FIPG), material and be careful not to drop any oil on the contact surfaces of the rear oil seal retainer and cylinder block.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the rear oil seal retainer as shown in the illustration.
Seal packing: Part No. 0882B-00080 or equivalent.
^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.
^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.