Remove the 6 bolts and 2 nuts.

0.906,2.781 1.969,2.979 1.969,2.979 2.656,2.521 false 1.875,3.01 2.063,3.188 0.188,0.177 10 *a

*a	Protective Tape

Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver as shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

HINT:

Tape the screwdriver tip before use.

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

Standard Thrust Clearance:

0.160 to 0.342 mm (0.00630 to 0.0135 in.)

Maximum Thrust Clearance:

0.342 mm (0.0135 in.)

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

1.219,0.115 1.177,0.115 1.177,0.115 0.771,0.76 false 1.229,0.052 1.938,0.198 0.708,0.146 10 *a

*a

Matchmark

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

HINT:

The matchmarks on the connecting rods and connecting rod caps are provided to ensure correct reassembly.

1.063,0.719 1.156,0.719 1.156,0.719 1.646,0.542 false 0.771,0.625 1.229,0.823 0.458,0.198 10 false SST

Using SST, uniformly loosen and remove the 2 connecting rod bolts.

SST

09205-16011  

Using the 2 removed connecting rod bolts, remove the connecting rod cap and connecting rod bearing by wiggling the connecting rod cap back and forth.

HINT:

Keep the connecting rod bearing inserted in the connecting rod cap.

1.167,0.25 1.281,0.25 1.281,0.25 1.708,0.854 false 0.979,0.167 1.188,0.344 0.208,0.177 10 *a

*a	Plastigage

Lay a strip of Plastigage on the crank pin.

0.959,0.044 1.162,0.194 0.203,0.15 10 *a 1.164,0.123 1.328,0.123 1.328,0.123 1.486,0.718 false

*a	Front Mark

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

0.323,0.429 0.63,0.572 0.307,0.143 10 SST 1.217,0.511 0.718,0.511 false

Step 1:

2.094,0.594 2.385,0.344 2.385,0.344 2.583,0.344 false 2.635,0.271 2.948,0.469 0.313,0.198 10 false *a 1.104,0.365 1.417,0.563 0.313,0.198 10 false 90°

*a	Paint Mark
	Engine Front

Step 2:

0.896,0.354 1.052,0.354 1.052,0.354 1.427,1.125 false 1.458,4.063 1.177,3.135 1.177,3.135 1.51,3.135 false 1.51,3.417 1.177,3.135 false 0.698,0.26 0.875,0.406 0.177,0.146 10 *b 0.979,3.01 1.125,3.156 0.146,0.146 10 *a

*a	Mark 1, 2 or 3
*b	Plastigage

Measure the Plastigage at its widest point.

Standard Oil Clearance:

0.014 to 0.038 mm (0.000551 to 0.00150 in.)

Maximum Oil Clearance:

0.070 mm (0.00276 in.)

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

NOTICE:

Remove the Plastigage completely after the measurement.

HINT:

If replacing a connecting rod bearing, replace it with one that has the same number as its respective connecting rod cap. Each connecting rod bearing standard thickness is indicated by mark 1, 2 or 3 on its surface.

Standard Connecting Rod Large End Bore Diameter:

Mark	Specified Condition
1	47.000 to 47.008 mm (1.85039 to 1.85070 in.)
2	47.009 to 47.016 mm (1.85074 to 1.85102 in.)
3	47.017 to 47.024 mm (1.85106 to 1.85133 in.)

Standard Connecting Rod Bearing Thickness:

Mark	Specified Condition
1	1.489 to 1.493 mm (0.058622 to 0.058779 in.)
2	1.494 to 1.497 mm (0.058819 to 0.058937 in.)
3	1.498 to 1.501 mm (0.058976 to 0.059094 in.)

Standard Crank Pin Diameter:

43.992 to 44.000 mm (1.7320 to 1.7323 in.)

Using a ridge reamer, scrape off any carbon on the top of the cylinder.

0.719,1.698 0.885,1.698 0.885,1.698 1.292,1.302 false 0.521,1.604 0.719,1.76 0.198,0.156 10 false *a

*a	Piston Ring Expander

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

Using a screwdriver, pry out the 2 piston pin hole snap rings.

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

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

HINT:

·

The piston and piston pin are a matched set.

·

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

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

Standard Thrust Clearance:

0.04 to 0.14 mm (0.00157 to 0.00551 in.)

Maximum Thrust Clearance:

0.18 mm (0.00709 in.)

If the crankshaft thrust clearance is more than the maximum, replace the upper crankshaft thrust washers as a set. If necessary, replace the crankshaft.

HINT:

The upper crankshaft thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 in.).

0.341,0.432 0.454,0.584 0.113,0.151 10 3 0.341,1.726 0.454,1.877 0.113,0.151 10 4 3.126,0.432 3.239,0.584 0.113,0.151 10 1 3.126,1.726 3.239,1.877 0.113,0.151 10 2 0.996,0.388 1.109,0.539 0.113,0.151 10 7 0.996,1.784 1.109,1.935 0.113,0.151 10 8 2.473,0.388 2.586,0.539 0.113,0.151 10 5 2.473,1.784 2.586,1.935 0.113,0.151 10 6 1.684,0.356 1.873,0.507 0.188,0.151 10 10 1.738,1.785 1.851,1.936 0.113,0.151 10 9

Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in the order shown in the illustration.

Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps and 5 crankshaft bearings.

NOTICE:

Insert the crankshaft bearing cap set bolts into the crankshaft bearing caps in turn. Ease the crankshaft bearing cap out by gently pulling up while wiggling it back and forth as shown in the illustration. Do not damage the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.

HINT:

·

Keep the lower crankshaft bearing and crankshaft bearing cap together as a set.

·

Arrange the crankshaft bearing caps in the correct order.

Remove the 2 upper crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.

Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the 5 lower crankshaft bearings from the 5 crankshaft bearing caps.

HINT:

Arrange the removed parts in the correct order.

Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.