CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01W58S

      Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

      Standard Thrust Clearance
      0.160 to 0.512 mm (0.00630 to 0.0202 in.)
      Maximum Thrust Clearance
      0.512 mm (0.0202 in.)

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01W0OOE01
      Text in Illustration
      *a Alignment Mark

      Check the alignment marks on the connecting rod and connecting rod cap to ensure correct reassembly.

    2. A01W42W

      Remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    3. Clean the crank pin and connecting rod bearing.

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

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

    5. A01W1UBE01
      Text in Illustration
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. A01W528E01
      Text in Illustration
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing in the correct direction, and install the connecting rod cap.

    7. A01W42W

      Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

    8. Install and alternately tighten the 2 connecting rod bolts in several steps.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    9. A01VZM0E41
      Text in Illustration
      *a Paint Mark
      B001OAO Engine Front

      Mark the front of each connecting rod bolt with paint.

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

      Note

      Do not turn the crankshaft during the measurement.

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

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    12. A01W591E01
      Text in Illustration
      *a Plastigage
      *b Number Mark

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.030 to 0.063 mm (0.00118 to 0.00248 in.)
      Maximum Oil Clearance
      0.07 mm (0.00276 in.)

      Note

      Remove the Plastigage completely after the measurement.

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

      Tech Tips

      If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

      Standard Crank Pin Diameter
      51.492 to 51.500 mm (2.02724 to 2.02756 in.)
      Standard Connecting Rod Big End Inside Diameter
      Mark Specified Condition
      1

      54.500 to 54.508 mm

      (2.14567 to 2.14598 in.)
      2

      54.509 to 54.516 mm

      (2.14602 to 2.14629 in.)
      3

      54.517 to 54.524 mm

      (2.14633 to 2.14661 in.)
      Standard Connecting Rod Bearing Center Wall Thickness
      Mark Specified Condition
      1

      1.486 to 1.490 mm

      (0.0585 to 0.0587 in.)
      2

      1.491 to 1.494 mm

      (0.0587 to 0.0588 in.)
      3

      1.495 to 1.498 mm

      (0.0589 to 0.0590 in.)

    13. Perform the inspection for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


    1. A01W54YE01
      Text in Illustration
      *a Ridge Reamer

      Using a ridge reamer, remove all the carbon from the top of the cylinder.

    2. Remove the 8 connecting rod bolts and 4 connecting rod caps.

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    3. Push the 4 piston with connecting rods and connecting rod bearing through the top of the cylinder block sub-assembly.

      Tech Tips


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

      • Arrange the removed parts in the correct order.

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

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the 8 connecting rod bearings from the connecting rods and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01W3T3

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard Thrust Clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum Thrust Clearance
      0.30 mm (0.0118 in.)

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

      Standard Thrust Washer Thickness
      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

  6. REMOVE CRANKSHAFT


    1. A01W1IEE04

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

    2. Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

      Tech Tips


      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.

      • Arrange the removed parts in the correct order.

    3. Remove the crankshaft from the cylinder block sub-assembly.

      Tech Tips

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

    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.

  7. REMOVE CRANKSHAFT THRUST WASHER


    1. A01W5PU

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

  8. REMOVE CRANKSHAFT BEARING


    1. Remove the 5 crankshaft bearings and 5 No. 2 crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  9. REMOVE CRANKSHAFT PULLEY KEY


    1. Using a screwdriver, remove the 2 crankshaft pulley keys from the crankshaft.

  10. REMOVE PISTON RING SET


    1. A01W51YE02
      Text in Illustration
      *a Piston Ring Expander

      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.

  11. REMOVE PISTON PIN HOLE SNAP RING


    1. A01W1K1E05
      Text in Illustration
      *a Protective Tape
      *b Cutout

      Using a screwdriver, pry out the piston pin hole snap ring (front side).

      Note


      • Do not remove the piston pin hole snap ring (rear side) unless it has to be replaced.

      • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).

      Tech Tips

      Tape the screwdriver tip before use.

  12. REMOVE PISTON


    1. A01W1W1

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

    2. A01W3S1

      Using a hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod sub-assembly.

      Tech Tips


      • The piston and piston pin are a matched set.

      • Be sure to arrange the removed pistons, piston pins, piston rings, connecting rod sub-assemblies and connecting rod bearings in such a way that they can be reinstalled exactly as before.

      • Arrange the removed parts in the correct order.

  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01VZE6

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

  14. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.