1) Preparations
- Tools/parts/measurement gear: OEM service manual (for torque/tolerances), engine hoist/stand if needed, torque wrench, torque-angle gauge, plastigauge, micrometer/inside micrometer, dial bore gauge, straightedge, feeler gauges, piston ring compressor, new rod bearings and caps (matched), new rod bolts if specified, assembly lube, clean rags, solvent.
- Why: correctness of tolerances and correct fasteners is critical to bearing life and safe reassembly. Measuring tools let you verify clearances rather than guess.

2) Diagnose and identify the fault (quick theory)
- Typical rod/bearing faults: rod knock (metallic knock at load), low oil pressure, metal particles in oil, high bearing wear on inspection.
- Root causes: oil starvation, contaminated oil/particles, incorrect clearance, fatigue/broken rod bolts, hydrolock bending rods, crank journal damage.
- Why diagnosis: different faults require different repairs (replace bearing vs. regrind crank, replace rods/bolts).

3) Access and strip to the rod assemblies (order)
- Drain oil; remove sump/oil pan and baffles; remove oil pickup if needed.
- Remove accessories that block access (flywheel/torque converter cover if required for big ends at bottom).
- Mark piston-to-rod orientation and cylinder numbers on each piston/rod (cap is matched to rod and orientation is critical). Keep assemblies in order.
- Why: pan removal gives access to rod caps; marking ensures correct reassembly — rods and caps are machined as matched pairs.

4) Remove rod caps and extract pistons
- Break rod-cap torque, remove cap bolts/nuts; remove cap while keeping bearing shells with cap/rod orientation.
- Push piston up into the cylinder and extract the piston/rod assembly through the top (if head removed) or remove from bottom if slipped out.
- Inspect rod bolts and caps for distortion, nuts for looseness.
- Why: careful removal preserves matched parts and prevents mixing; inspecting fasteners may reveal bolt stretch or damage that caused failure.

5) Clean and inspect components (theory-focused checks)
- Clean all oil galleries; check bearings for pattern: failure shows darker scored lines, polish, or severe gouging.
- Measure rod small end and big-end bores, measure crankshaft journal diameters with micrometer, and measure bearing bores if rebushing required.
- Check rod straightness (bench gauge) and cracks with dye-penetrant or magnaflux (if available).
- Measure bearing clearances using plastigauge or by measuring journal and new shell thickness and computing clearance.
- Why: bearings fail when clearance is wrong (too tight → seizure, too loose → knock). Crank journals out of round or undersize require grinding or replacement.

6) Decide repair path (replace bearings vs. regrind/crankshaft work/rod replacement)
- If journals are within OEM spec and only bearings worn: replace rod bearings with OEM-size shells.
- If journals scored/out-of-round beyond spec: crankshaft regrind + undersize bearings OR crankshaft replacement.
- If rod is bent/cracked or bolts stretched: replace rod assembly and bolts.
- Why: replacing bearings alone restores oil film clearance if journals are sound. If journal geometry is wrong, new shells won't restore hydrodynamic film and failure will recur.

7) Prepare parts for reassembly
- Install new bearing shells into rod and cap; ensure oil holes/grooves align.
- If using new bolts, fit them dry; if bolts are torque-to-yield (check manual) they must be replaced.
- Clean mating surfaces; lightly oil bearing surfaces with assembly lubricant.
- Why: correct bearings and fasteners ensure correct preload and predictable clamp force — essential for maintaining film thickness under load.

8) Reassembly order and checking clearances
- Fit piston/rod into cylinder (if head on, use ring compressor) and position rod on journal.
- Place cap and snug bolts by hand, then follow tightening sequence to specified torque or torque-angle in stages per OEM.
- Check bearing clearance with plastigauge: tighten to spec, remove cap, measure width of flattened plastigauge against scale. Refit with correct bearings if outside range.
- After correct clearance confirmed, final torque bolts to spec.
- Why: plastigauge verifies the actual oil clearance (hydrodynamic oil film thickness). Correct torque ensures clamp force that controls bearing clearance under operating load.

9) Final checks before closing
- Rotate crank by hand several revolutions; check for smoothness and no tight spots.
- Measure crankshaft endplay and main bearing clearances if disturbed.
- Reinstall oil pickup and pump strainer; prime oiling system (turn oil pump by hand or crank engine with no fuel/ignition to build pressure).
- Refit sump, filters, and fresh oil.
- Why: priming prevents dry start; checking rotation ensures no interference; endplay and pump health affect oil pressure.

10) Run-in and verification
- Start engine and monitor oil pressure and noises. Run at low load for initial minutes, then gradually increase load. Re-check torque on rod bolts after initial run if manual recommends.
- Check for metal in oil filter and magnetic drain plugs.
- Why: initial run-in allows bearings to settle; early recheck catches any bolt relaxation or early failures.

How the repair fixes common faults (concise)
- Bearing wear/knock from oil starvation/contamination: Replacing bearings and cleaning oil galleries restores the correct oil clearance and prevents metal-to-metal contact; cleaning pickup and filter ensures restored oil flow and pressure.
- Incorrect bearing clearance/torque: Measuring and setting correct clearance with correct torque restores hydrodynamic oil film thickness so bearings carry load on an oil wedge instead of metal contact.
- Crank journal damage: Regrinding journals to undersize + matching bearings restores roundness and correct diameter; if journals are replaced or machined true, the oil film geometry is re-established.
- Bent/broken rod or stretched bolts: Replacing rod/bolts restores geometry and clamp strength; new, non-stretched bolts maintain correct preload preventing cap separation and bearing movement.
- Contamination/corrosion: Thorough cleaning, new bearings, new oil and filter remove abrasive particles and prevent repeated wear.

Key theory points to remember (no fluff)
- Rod bearings operate on hydrodynamic lubrication: a continuous oil wedge carries the load; correct clearance, journal roundness, surface finish and oil pressure are essential.
- Bolt clamp force controls bearing clearance under dynamic load; torque-to-yield bolts cannot be reused.
- Bearing failure symptoms are diagnostic: fatigue (pitting), abrasive (scoring), excessive clearance (knock), seizure (polishing/raised metal).
- Always verify with measurements rather than relying on feel.

Final brief cautions
- Use OEM torque and clearance specs from the Hino GH1H service manual exactly.
- Replace torque-to-yield/stretch bolts per manual.
- Cleanliness and oiling during assembly are as important as dimensional accuracy.

That’s the ordered procedure with the underlying theory and how each repair action corrects the fault.
rteeqp73

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