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ENGINE OVERHAUL
INSPECTION
(1) Wash all parts in a suitable solvent and
for damage or wear.
(2)Mating surface of the oil pump should be smooth. Replace
pump cover if scratched or
(3)Lay a straightedge across the pump cover surface.
a feeler gauge of 0.076 mm ‘in.) or more can be
inserted between cover and straightedge, cover shou ld
be replaced.,
Limit: 0.076 mm in,)
(4 Measure thickness and diameter of outer rotor. If outer
rotor thickness measures 7.64 mm
in.) or less, or
if the diameter is 79.95 mm (3.148 in.) or less, re place
outer rotor.
(5) If inner rotor measures limit or less, replace inner rotor.
Limit: 7.64 mm in.)
(6) Slide outer rotor into pump housing, press to o ne side
with fingers and measure clearance between rotor an d
housing. If measurement exceeds the limit, replace hous-
ing only if outer rotor is in specification.
Limit: 0.39 mm in.)
Page 250 of 2103
1E N G I N E - ‘ O i l
Feeler
Outer0rotor
G a s k e tI
(7) Install inner rotor into pump housing. If clear ance between
inner and outer rotors exceeds the limit, replace b oth
rotors.
Limit: mm in.)
(8) Place a straightedge across the face pump
between bolt holes. a feeler mm
in.) or more can be inserted and
straightedge, replace pump
Limit: 0.102 mm ,
(9) Inspect oil pressure relief valve plunger for scoring-and.
free operation in its bore. Small marks may. be rem oved,
with wet or dry sandpaper.
relief valve spring has a free length
60.7 mm (2.39 in.). It should test between -and
when compressed to 40.5 mm (1.60 in.). ,
that fails to meet specifications.
.
oil pressure is and pump is within
inspect for worn engine bearings, or other for
oil pressure loss.
. .
, __ . ,
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Page 251 of 2103

Piston,
ENGINE and Cylinder
Rearcrankshaft seal
metal caseEngine
Engine block
crankshaft seal
crankshaft seal
dust lip
PISTON, CONNECTING ROD
CYLINDER BLOCK
REMOVAL
(1) insert a flat ‘screwdriver between the dust
lip and the metal case of the seal.
Angle the screwdriver through the dust lip metal
case of the seal. Pry out seal.
Caution
Do not permit the blade c o n t a c t
crankshaft seal surface. Contact of the screwdriver
blade crankshaft edge (chamfer) is permitted.
(2) Remove top ridge of cylinder bores with areliable ridge
reamer before removing pistons from cylinder block.
Be sure to keep tops of pistons covered during this opera-
tion. Mark piston with matching cylinder number.
(3) Ensure connecting rods and connecting rod caps match
and proper set for the cylinder number. Identify them
if necessary.
(4) Pistons and connecting rods must be removed fro m top
of cylinder block. Rotate crankshaft so that each connect-
ing rod is centered in cylinder bore.
(5) Remove connecting rod cap bolts. Push each pist on
and rod assembly out of cylinder bore.
Be careful not to nick crankshaft journals.
(6) After removal, install bearing cap in the conne cting
orientation on the mating connecting rod.
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Page 252 of 2103
11ENGINE OVERHAUL and
Piston, Rod
D I S A S S E M B L Y
(1) Separate piston from rod by removing piston
pin.
(2) a suitable ring expander,, remove and inter-
mediate piston rings.
(3) Remove the upper oil ring side rail, lower oil ring side
rail and then oil ring expander from piston.
(4)
ring grooves of any carbon deposits.
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Page 253 of 2103
Rod
ENGINE and Cylinder
I
Front of engine
REASSEMBLY
(1) Install rings with manufacturer’s mark facing up, to-
ward the top of the piston.
Caution
Install piston rings in the following order:
(a) Oil ring expander.
(b) Upper oil ring side rail.
(c) Lower oil ring side rail.
(d) No. 2 intermediate piston ring.
(e) No. 1 upper piston ring.
(2) Install the side rail by placing one end betwee n the piston
ring groove and the expander. Hold end firmly and p ress
down the portion to be installed until side rail is in position.
Do not use a piston ring expander.
(3) Install upper side rail first and then the lowe r side rail.
(4) Install No. 2 piston ring and then No. 1 piston ring.
(5) Position piston ring end gaps as shown in the f igure.
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Piston,ENGINE OVERHAUL and Cylinder
(6) Position ring expander at 45
the side gaps but ‘on the pin canter
on the thrust direction. Staggering important
for
control.
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Page 255 of 2103
piston,
ENGINE
(1) Before installing pistons and connecting rod assemblies
into the bore, be sure that compression ring gaps a re
staggered so that neither is in line with oil ring rail gap.
Front of engine
(2) Before installing the ring compressor, make sur e the
ring expander ends are butted and the rail
as shown in the figure.
.
(3) Immerse the piston head and rings in clean engine oil,
slide the ring compressor, over the piston. Be sure that
position of rings does not change during this opera tion.
(4) The arrow should face toward the front of the engine.
Install the pistons.
(5) Rotate crankshaft so that the connecting journal is
on the center of the cylinder bore. rod and piston
assembly into cylinder bore and guide rod over the crank-
shaft journal.
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Piston, ConnectingENGINE OVERHAUL and
(6) Tap the piston down in cylinder bore, using a hammer
handle. At the same time, guide connecting rod into
position on connecting rod journal.
(7) Install connecting rod bearings selected based
obtained connecting rod bearing
(Refer to CONNECTING ROD BEARING CLEARANCE.)
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