CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 VENTILATION CASE

    Tech Tips

    There are 2 installation methods for the No. 1 ventilation case.

    Depending on the installation method, the number of bolts, nuts and stud bolts used will vary.


    1. A001SR4

      for Type A:

      Remove the 6 bolts and 2 nuts.

    2. A001WO9

      for Type B:

      Remove the 8 bolts.

    3. A001TX3C04
      *a Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  2. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A001UGI

      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.)

      Tech Tips

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

  3. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A001T7UC04
      *a Matchmark

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

      Tech Tips

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

    2. A001TB6E02

      Using SST, uniformly loosen the 2 connecting rod bolts.

      SST
      09205-16011
    3. A001WKX

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

      Tech Tips

      Keep the crankshaft bearing inserted in the connecting rod cap.

    4. Clean the crank pin and connecting rod bearing.

    5. Check the crank pin and connecting rod bearing for pitting and scratches.

      Tech Tips

      If the crank pin or connecting rod bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

    6. A001T4MC14
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    7. A001XJYC05
      *a Front Mark

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

    8. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

    9. Install the connecting rod bolts.

      Note

      The connecting rod bolts should be tightened in 2 progressive steps.

    10. A001UYQE02

      Step 1:


      1. Using SST, install and alternately tighten the 2 connecting rod bolts of the connecting rod cap in several steps.

        SST
        09205-16011
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Note

        Do not turn the crankshaft.

    11. A001WTOC78
      *a Paint Mark
      *b 90°
      B008LL0 Engine Front

      Step 2:


      1. Mark the front of the connecting rod bolts with paint.

      2. Tighten the connecting rod bolts by 90° as shown in the illustration.

        Note

        Do not turn the crankshaft.

    12. Remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the crankshaft bearing inserted in the connecting rod cap.

    13. A001WFLC10
      *a Plastigage
      *b 1, 2 or 3 Mark

      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.)

      Note

      Remove the Plastigage completely after the measurement.

      Tech Tips


      • 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 a 1, 2, or 3 mark on its surface.

      • If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

      Standard Connecting Rod Large End Bore Diameter
      Mark Specified Condition
      1 50.000 to 50.008 mm (1.9685 to 1.96881 in.)
      2 50.009 to 50.016 mm (1.96886 to 1.96912 in.)
      3 50.017 to 50.024 mm (1.96917 to 1.96944 in.)
      Standard Connecting Rod Bearing Thickness
      Mark Specified Condition
      1 1.489 to 1.493 mm (0.05862 to 0.05878 in.)
      2 1.494 to 1.497 mm (0.05882 to 0.05894 in.)
      3 1.498 to 1.501 mm (0.05898 to 0.05909 in.)
      Standard Crankshaft Pin Diameter
      46.992 to 47.000 mm (1.85008 to 1.85039 in.)

    14. Perform the inspection above for each cylinder.

  4. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A001SQ7

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

    2. Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block sub-assembly.

      Tech Tips


      • Keep the connecting rod bearing, connecting rod and connecting rod cap together.

      • Arrange the pistons and connecting rods in the correct order.

      • Be sure to arrange the removed pistons and connecting rods in such a way that they can be reinstalled exactly as before.

  5. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  6. REMOVE PISTON RING SET


    1. A001UAT

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

    2. Remove the oil ring expander, upper side rail and lower side rail by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE PISTON


    1. A001V7N

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

    2. A001VK6

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

      CAUTION:

      Be sure to wear protective gloves.

    3. A001TC2

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

      Tech Tips


      • 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.

  8. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A001T5S

      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.)

      Tech Tips

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

      Standard Thrust Washer Thickness
      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

  9. REMOVE CRANKSHAFT


    1. A001SNAE01

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

    2. A001VM5

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

      Note

      Insert the crankshaft bearing cap set bolts into the caps in turn. Ease the crankshaft bearing cap out by gently pulling up while applying force toward the front and back sides of the cylinder block sub-assembly as shown in the illustration. Take care not to damage the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.

      Tech Tips


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

      • Arrange the crankshaft bearing caps in the correct order.

    3. Lift out the crankshaft.

    4. Check each crankshaft journal and crankshaft bearing for pitting and scratches.

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

  10. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A001XMF

      Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.

  11. REMOVE CRANKSHAFT BEARING


    1. A001TQG

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

      Tech Tips

      Arrange the crankshaft bearings in the correct order.

    2. A001TBC

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

      Tech Tips

      Arrange the removed parts in the correct order.

  12. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A001URM

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

  13. CLEAN CYLINDER BLOCK SUB-ASSEMBLY

    Note

    If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block sub-assembly. Always wash the cylinder block sub-assembly at a temperature of 45°C (113°F) or less.