ãã(a) Check the matchmarks on the connecting rod and cap to ensure correct reassemi.:y.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
HINT: Keep the lower bearing inserted with the .con- necting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scrat~ ã ches.
If the crank pin or bearing is damaged, replace the bearings. If nece:;sary, grind or replace the crankshaft ..
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See step B in cylinder block assembly) Torque:ã
1st: 24.5 Nãm (250 kgfãcm, f 8 ft-Jbf) 2nd: Turn go•
NOTICE: Do not turn til<. cronbhaft.
(hj Ramovo the 2 bolts and connecting rod cap.
(Sa~ procedure (b) and (c) abova)
(i) Measur~ the Plastigage at its widest point.
Standard oil c!oarance:
STD:
0.020 - 0.048 mm (0.0008 - 0.0019 ln.) U/S 0.25, U/S 0.50 end U/S 0.75:
ã. O.o19 - 0.068 mm (0.0007 - 0.0022 ln.) Maximum oil clearance:
0.08 mm (0.0031 ln.)
If the oil'. clearance is greater than maximum, replace . the bearings. If necessary, grind or replace the crank- shaft.
ENGINE
Mark ~
1, 2 or 3 (
I -,~'ã'"'' M••
(Protrusior.)
Ul 4.
(a) (b)
' (c)
.. • -•
' 5.
-~ 2 6.
(a)
ãã• .. ~
ENGINE MECHANICAL EG-37
HINT: If using a standard bearing. replace it with one having the same number marked r,n the connocting
ãrod cap. There are three sizes of standard hearings, marke<1 '1", "2" and '3" accordingly.
Standard sized bearing cantor well thickness:
STD-Mark ~ 1.488 - 1.490 mm (0.05S5 - 0.0587 ln.) STD Mark 2 1.490 - 1 .494 mm (0. 0587 - 0.0588 in.) STD Mork 3 1.494 - 1.498 mm (0.0588 - 0.0590 ln.) u;s o.25 1.807 - 1.813 mni (0.0833 - 0.0835 in.)
u;s o.so 1.732 - 1.738 mm (0.0682 - 0.0684 in.) u;s o.75 1.857 - 1.883 mm (0.07 ~ 1 - 0.0733 ln.)
Completely remove the Plastigage.
REMOVE PISTON AND CONNECTlNf> ROD ASSEMBLIES
Using a ridge reamer, remove the all carbon fromãthe top of the cylinder.
Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from daml'ige.
Push the piston, connecting rod assembly and upper bearing through the top of the cylindGr bloc;k.
HINT:
• Keep the bearings, connecting rod and cap to- gather.
• Arrange the piston a11d conn&cting rod al;sernbl- ies in correct order.
CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back ~nd forth with a screwdriver.
Standard thruat clearance:
0.040 - 0.242 mm (0.0016 - 0.0095 ln.) MGxlmum thrust clearance:
0.30 mm (0.0118 ln.)
If the thrust clearance is greater than maximum, re- plaol' tha thrust washers as a sat.
Thruot washer thlckne .. :
STD 2.430 - 2.480 mm (O.OU57 - 0.0978 ln.) 1
I
0/S 0.126 2.490 - 2.540 mm (0.0980 - 0.1 000 ln.)
REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE
Uniformly loosen and remove the 1 0 main bearing cap bolts in several passes, in the sequence shown.
EG-38
Plastigage
ENGIN'E '-' ENGINE MECHANICAL
(b) Using the'removecl main bearingã cap bolts. pry the • main bearing cap back and forth. and remove the main ã bearing caps. lower bearings and lower thrust wash- ers (No:3 main bearing cap only) ..
HINT:
• Keep the lower bearing. and main bearing cap together.
• Arrange the main bearing caps and lower thrust washers in correct ord.er.
(c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust wash- ers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bear.ing for pitting and scratches.
If the journal or bearing is damaged, replace the bear- ings, If necessary, grind or repiace the crankshaft.
(f)ã Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the 5 main bearing caps witb the 10 bolts.
(Soe step 4 in cylinder block assembly) Torqãuo: 59 Nãrn (600 kgf.cm. 43 ftãlbf) NOTICE: Do not turn the crankshaft.
(i) Remove the 10 bolts and 5 main bearing caps.
(See procedure (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD 0.016 - 0.040 mm (0.0006 - 0.0016 in.) U/S typo 0.017 - 0.071 mm (0.0007 - 0.0028 in.)
Maximum:
0.10 mm (0.0039 in.)
-
If the oil clearance is greater than maximum. replace the bearings. If necessary. grind or replace the crank- shaft.
.ã
~ãã ..
"!
•.
. ' ENGINE - ENGINE MECHANICAL ã ã ãã EG-39 . ã- . . ' . ~ . : '• ... ã ..
. .. 1:'/0,3 r=-.
No!~'{t"
'"' ã ' , ~/.%" Mark
~ :r;::.. 0 6,7or8
j~ ;---. LjJ """ .
P25&51 P25584 P25681
\).\)>:::;;;>Mark 3,4,5,6 or 7
ZI6SJS
ãHINT: If l'!Sing ãa standard bearing, replace with one having the same number. If the number of the bearingã
c2nnot be determined, select a beãaring from the table according to the numbers imprinted on tf':q r.vlinder blockã andãcrankshaft. ThtJre are 5 sizes of standardã
bearings, marked "3", "4", ãsã. "6" ond "7" accordingly.
NumbP.r marked
Cylinder block 6 7 8
Crankshaft 1 213 t 12 3 1 2 Use bear!ng 5 4i3 6!5 4 7 6 EXAMPLE: Cylinder block "6'' - Crankshaft "2"
= Total number 4 (Use bearing "4")
Reference:
Cylinder block main Journal bore diamotAr:
Mark 6 54.004 - 54.012 mm (2. J 201 - 2.1265 in.}
Mark 7 54.012- 54.020 mm (2.1255- 2.1268 in.) Mark 8 54.020- 54.028 mm (2.1268- 2.1271 ln.)
Crankshaft Journal diamEltor:
Mark 1 49.976 49.984 mm (1.9796- 1.9679 in.) Mcrk 2 49.984 49.992 mm (I .967~ - 1.9682. in.Jã
Mark 3 49.992 50.000 mm.(l.9d82 - 1.96851o.) u;s o.25 49.733 - 49.743 mm t1.958Cl- 1.9584 in.) U/S 0.50 49.483 - 49A03 mm (!.9481 - 1.9485 in.)
Standard :oizod bearing cent'er Wfl!l.t:hicKnoss:
Mark 3 I .990 - 1.994 mm (0.0703 - 0.0785 ln.l
3 5
Mark 4 1.994ã- !.9S8 mm (0.0785 - 0.0787 ln.) ---
,_f~rk. sã 1.998 2.002 mm. (_O.o787 -ã 0.0708 l n R Mark B 2.002 - 2.006 mm (0.07ell - 0.0790 ln.) ; Made 7 2.006- 2.0!0 mrn (0.07PO- 0.0791 in.) •
~- IJ , .. 0 2r.:: -- --ãã
' J., • • l 2.112 - 2. I 2~ m:n t0.0~3 I - 0.0835 lr.J
L:u;so.so -
2.237 - 2.247 mm (O.OU8l - 0.0885 _ln.)
(k) Corupletely remove tha Plastig~ge . . 7. - REMOVE CRANKSHAFT
(a) ãLift out the crankshaft.
J 1
(b)ã Remove the upper bearings andã upper thrust washers fromã.the cylinder block.
HINT: Arrange the main bearing caps, bearbgs and thrust washers in correct order.
~ ~
~~.. • i ..
r;. EG-40
11:). I .. ENGINE :.-ã.ENGINE MECHANICAL , ..
,---~~~~~~~~~~~~~~~---
P25!'i2J f'25524'
ã--
o oão oão oão o
rf- '\9!: ~ ~
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---:="""'
:ã . CYLINDERã BLOCK INSPECTION
, ... " ... ãã.: . , ...
1- CLEANãCYLINDER BLOCK A. Remove gasket material
--11
..
ã Using a gasket scraper, remove all the gasket material from the top surface of the cylind~r block.
B. Clean cylinder block
Using a soft. brush and solvent; thoroughly clean the cylinder block.