Page 161 of 4770
3. INSPECT CONNECTING ROD
A. Inspect connecting rod alignment
Using a rod aligner and thickness gauge, check the
connecting rod alignment.
wCheck for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 In.)
If bend is greater than maximum, replace the connect±
ing rod assembly.
wCheck for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connect±
ing rod assembly.
B. Inspect piston pin oil clearance
(a) Using a caliper gauge, measure the inside diameter of
the connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.017 mm (0.8663 ± 0.8668 in.) D. Inspect±piston pin fit
At 60C (140 F), you should be able to push the
piston pin into the piston pin hole with your thumb.
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 ± 22.009 mm (0.8660 ± 0.8865 in.)
± 5S±FE ENGINEENGINE MECHANICALEG1±111
Page 162 of 4770
(c) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance:
0.05 mm (0.0020 In.)
If the oil clearance is greater than maximum, replace
the bushing. If necessary, replace the piston and
piston pin as a set.
(b) Align the oil holes of a new bushing and the connect±
ing rod.
(c) Using SST and a press, press in the bushing.
SST 09222±30010
(e) Check the piston pin fit at normal room temperature.
Coat the piston pin with engine oil, and push it into the
connecting rod with your thumb. (d) Using a pin hole grinder, hone the bushing to obtain
the standard specified clearance (see step B above)
between the bushing and piston pin. C. If necessary, replace connecting rod bushing
(a) Using SST and a press, press out the bushing.
SST 09222 ± 30010
± 5S±FE ENGINEENGINE MECHANICALEG1±112
Page 163 of 4770
(b) If the cap nut cannot be turned easily, measure the
outside diameter of the connecting rod bolt with a
vernier caliper.
Standard outside diameter:
7.860±8.000 mm (0.3094±0.3150 in.)
Minimum outside diameter:
7.60 mm (0.2992 in.)
HINT: If the location of this area cannot be judged by
visual inspection, measure the outer diameter at the
location shown in the illustration.
If the outside diameter is less than minimum, replace
the connecting rod bolt and nut as a set. D. Inspect connecting rod bolts
(a) Install the cap nut to the connecting rod bolt. Check
that the cap nut can be turned easily by hand to the
end of the thread.
± 5S±FE ENGINEENGINE MECHANICALEG1±113
Page 164 of 4770
2. CALCULATE AMOUNT TO BORE CYLINDERS
(a) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 23.5 mm
(0.925 in.) from the piston head.
(b) Calculate the amount of each cylinder is to be rebored
as follows:
Size to be rebored = P + C±H
P = Piston diameter
C = Piston clearance
0.14 ± 0.18 mm (0.0055 ± 0.0063 in.)
H = Allowance for honing
0.20 mm (0.0008 in.) or less
3. BORE AND HONE CYLINDER TO CALCULATED
DIMENSIONS
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE: Excess honing will destroy the finished round±
ness.
CYLINDER BORING
HINT:
wBore all the 4 cylinders for the oversized piston
outside diameter.
wReplace all the piston rings with ones to match
the oversized pistons.
1. KEEP OVERSIZED PISTONS
Oversized piston diameter:
O/S 0.50
87.35 ± 87.38 mm (3.4390±3.4402 in.)
± 5S±FE ENGINEENGINE MECHANICALEG1±114
Page 165 of 4770

CRANKSHAFT INSPECTION AND REPAIR
1. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.06 mm (0.0024 In.)
If the circle runout is greater than maximum, replace
the crankshaft.
2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD size
54.988 ± 55.003 mm (2.1653±2.1655 in.)
U/S 0.25
54.745 ± 54.755 mm (2.1553±2.1557 in.)
Crank pin diameter:
STD size
51.985 ± 52.000 mm (2.0466±2.0472 in.)
U/S 0.25
51.745 ± 51.755 mm (2.0372±2.0376 in.)
If the diameter is not as specified, check the oil clear±
ance (See pages EG1±98 to 104). If necessary, grind
or replace the crankshaft.
(b) Check each main journal and crank pin for taper and
out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of±round is greater than maxi±
mum, replace the crankshaft.
3. IF NECESSARY. GRIND AND HONE MAIN JOUR±
NALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to
the finished undersized diameter (See procedure in
step 2).
Install new main journal and/or crankshaft pin under±
sized bearings.
± 5S±FE ENGINEENGINE MECHANICALEG1±115
Page 166 of 4770
B. If oil pump is installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft. Tape
the screwdriver tip.
CRANKSHAFT OIL SEALS
REPLACEMENT
HINT: There are 2 methods (A and B) to replace the oil
seal which are as follows:
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the oil pump case edge.
SST 09223 ± 63010
(c) Apply MP grease to the oil seal lip. 1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If oil pump is removed from cylinder block:
(a) Using a screwdriver and a hammer, tap out the oil
seal.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump case edge.
SST 09226 ±10010
± 5S±FE ENGINEENGINE MECHANICALEG1±116
Page 167 of 4770
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the rear oil seal edge.
SST 09223±63010
(c) Apply MP grease to the oil seal lip.
B. If rear oil seal retainer Is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft. Tape
the screwdriver tip.
2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder
block:
(a) Using screwdriver and hammer, tap out the oil seal.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223 ± 63010
± 5S±FE ENGINEENGINE MECHANICALEG1±117
Page 168 of 4770
PISTON AND CONNECTING ROD
ASSEMBLY
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a new snap ring on one side of the piston pin
hole.
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the piston
pin hole.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.(b) Gradually heat the piston to 80±90C
(176±194F).
± 5S±FE ENGINEENGINE MECHANICALEG1±118