Page 257 of 2103
Rod
a n d
(8) Install each bolt finger tight then alternately torque each
nut to. assemble the cap properly.
(9) Tighten the bolts to 27.0 Nm PLUS turn (20
PLUS turn). Do not use a torque wrench for last
step.
Oil seal
95059
seal
8995060
I
(lO)Using a feeler gauge, check connecting rod’ sid e clear-’
Standard value: mm in.)
Limit 0.37 mm
in.)
Caution
If burr’or scratch is present on the edge
(chamfer), cleanup with 400 grit paper to prevent
seal damage during’
new’
NOTE
When installing seal, no lube on seal is needed.
(11) Place Special Tool on crankshaft. This is a
pilot tool with a magnetic base.
seal over pilot tool. Make sure you can read
the words THIS SIDE OUT on seal. Pilot tool should
remain on crankshaft during
of seal.
the seal into the block using Special Tool
and handle until the tool bottoms out against
the block.
Caution
If the seal is driven into the past flush,
may cause an oil leak.
Page 258 of 2103

11
Piston, Connecting Rod
ENGINE OVERHAUL and
INSPECTION
BLOCK
(1) Clean cylinder block thoroughly and check all core hole
plugs for evidence of leaking.
(2) Examine block and cylinder bores for cracks or fractures.
Front
A
CYLINDER BORE
(1) The cylinder walls should be checked for out-of-round
and taper with Tool or equivalent cylinder
bore out-of-round is 0.051 mm in.) maximum, and
cylinder bore taper is 0.051 mm in.)
If the cylinder walls are badly scuffed or’scored, the cylin-
der block should be rebored and pistons
and rings fitted.
Whatever type is
used, boring and honing should be closely
with the fitting of pistons and rings so that speci fied clear-
ances may be maintained.
(2) the cylinder bore at three levels in directions
A and B. Top measurement should be 10 mm
in.)
down and bottom measurement should
mm
in.) up from bottom of bore.
Standard value: 87.5 mm (3.445 in.)
PISTONS
(1) Piston and cylinder wall must be clean and dry. Piston
diameter should be measured 90 degrees to piston pi n
at size location shown in the figure. Cylinder bores should
be measured halfway down the cylinder bore and tran s-
verse to the engine crankshaft center
Correct piston
to bore clearance must be established in order to a ssure
quiet and economical operation.
Standard value: mm 7 in.)
(2) Pistons and cylinder bores should be measured a t normal
room temperature, 21
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Page 259 of 2103
Piston,
E N G I N E
PISTON RING
(1) Wipe cylinder bore clean. Insert ring and push down
with piston to ensure it is square in bore. The rin g gap
measurement must be made with the ring positioning
at least 12mm in.) from bottom of bore.
Check gap with feeler gauge.
Standard value:
Upper ring
mm
Intermediate ring mm in.)
Oil
ring mm
Limit:
Upper ring 0.8 mm in.)
Intermediate ring 1.0 mm
in.)
Oil control ring 1.0 mm
in.)
(2) Check piston ring to groove side clearance..
Standard in.)
Limit: 0.10 mm
,
.
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings. All upper
bearing shells in the crankcase have oil grooves. All lower
bearing shells installed in the (bedplate) main bea ring caps
are plain. Crankshaft end play is controlled by a flanged bear-
ing on the number three main bearing journal.
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Page 260 of 2103

piston,
ENGINE OVERHAUL Cylinder Block
CONNECTING BEARING
(1) Place a piece of Plastigage across the, width of
bearing in the cap 6.35
mm off center and away -from the hole.
suspect areas can be checked, by placing in
the suspect area.
(2) Before assembling the rod with in place;
‘the crankshaft must be rotated the connecting rod
being checked starts moving toward the top of the e ngine.,
Only then should the cap be and torqued
to the specification.
Do not rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inaccurate re-
sults.
(3) Remove the bearing cap and compare the width of the
flattened Plastigage with the metric scale provided on
the package.
Standard value: mm in.)
Limit: 0.075 mm
in.)
bolt
Threads are not straight on line
Threads are straight
line,
bolt
CONNECTING ROD BEARING ,
(1) Since the connecting rod bearing cap are
using a new procedure, they should examined BE-
FORE reuse. If the threads are necked’
the bolts.
(2) Necking can be checked by holding a scale
edge against the threads. If all the threads contact,
the scale, the bolt should be replaced. .
,
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Page 261 of 2103
OVERHAUL
CRANKSHAFT
REMOVAL
Procedures after removing crankshaft sprocket, oil pan, pis-
tons and connecting rods.
(1) Using Tool remove front crankshaft oil seal.
Be careful not to damage the seal surface of cover.
(2) out rear seal with screwdriver. Becareful not to nick
or damage crankshaft flange seal surface or retaine r bore.
(3) Remove main bearing cap
(4) Remove bearing lower.
(5) Remove crankshaft.
(6) Remove bearing upper.
(7) Remove knock sensor.
(8) Remove oil pressure switch.
(9) Remove oil level gauge (dipstick).
Revision
Page 262 of 2103
ENGINE Crankshaft
Oil holes
I N S T A L L A T I O N
(1) Install oil level gauge (dipstick).
(2) Install oil pressure switch.
,
,
(3) Install knock sensor. Tighten knock sensor to 10 Nm
(7 torque. Over or under tightening effects knock
sensor performance, possibly causing improper spark con-
t r o l .
(4) Select proper thickness main bearing shells by referring
to CRANKSHAFT BEARING CLEARANCE.
NOTE
Upper and lower No. 3 bearing halves are flanged to
carry the crankshaft thrust loads and are NOT inter change-
able with any other bearing halves in the engine. Bearing
shells are available in standard and the following under-
sized:
0.016 mm, 0.032 mm, 0.250 mm.
Never install an undersize bearing that will reduce clear-
ance below specifications.
(5) Install the main bearing shells with the lubric ation groove
in the cylinder block.
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Page 263 of 2103
ENGINE OVERHAUL
NOTE
All upper bearing
in the crankcase have oil grooves.
All lower bearing shells installed in the (bedplate ) main
bearing caps are plain. Crankshaft end play is cont rolled
by a flanged bearing on the number three main beari ng
journal.
(6) Make certain oil holes in block line up with oi l hole in
bearings and bearing tabs seat in the
tab slots.
(7) Oil the bearings and, journals and install cran kshaft.
Caution
D o get oil on
If may effect the sealer ability the
to cylinder block.
(8) Apply 1.5 to 2.0 mm to in.) bead of Loctite
19614 to cylinder block as shown the figure.
(9) Install main bearing cap together with lower’
bearing shells.
Caution
Use only the specified “on
or damage to
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Page 264 of 2103
11E N G I N E.
installing the bolts, the threads should be oiled
with engine oil.
Crankcasebaffle
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main bearing to engine block bolts
thru finger tight, then torque main bearing bolts to
75 Nm (55
in sequence shown in the figure.
main bearing to engine block bolts (A
thru finger tight, then torque each bolt to 28 Nm (20
in sequence shown in the figure.
crankcase baffle into the opening in the
Attach baffle to main bearing fasteners.