CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01WXOC

      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. A01WYSQC03
      *a Paint Mark

      Place a paint mark across each corresponding connecting rod and connecting rod cap.

      Tech Tips

      The paint marks are used to ensure that the same parts are installed in the same combination to their original locations.

    2. A01WYHE

      Using a 12 mm bi-hexagon wrench, 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. A01WYDKC05
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. A01WXA7C02
      *a Front Mark

      Check that the front mark on the connecting rod cap is facing forward, and then install the connecting rod cap to the connecting rod.

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

    8. A01WYHE

      Using a 12 mm bi-hexagon wrench, install and alternately tighten the 2 connecting rod bolts in several steps.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

      Do not turn the crankshaft during the measurement.

      If a connecting rod bolt cannot be tightened to the specified torque, replace it.

    9. A01WYHKC01
      *a Paint Mark
      *b 90°
      B004FMB Front of Engine

      Mark the front of each connecting rod bolt with paint.

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

      Note

      Do not turn the crankshaft during the measurement.

    11. Using a 12 mm bi-hexagon wrench, remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    12. A01WXHIC05
      *a Number Mark
      *b Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.030 to 0.063 mm (0.00118 to 0.00248 in.) or 0.033 to 0.063 mm (0.00130 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 bearing. 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 Connecting Rod Diameter
      Item Specified Condition
      Mark 1

      54.500 to 54.508 mm

      (2.14567 to 2.14598 in.)
      Mark 2

      54.509 to 54.516 mm

      (2.14602 to 2.14629 in.)
      Mark 3

      54.517 to 54.524 mm

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

      1.486 to 1.490 mm

      (0.05850 to 0.05866 in.)
      Mark 2

      1.491 to 1.494 mm

      (0.05870 to 0.05882 in.)
      Mark 3

      1.495 to 1.498 mm

      (0.05886 to 0.05898 in.)
      Standard Crank Pin Diameter
      51.492 to 51.500 mm (2.02724 to 2.02756 in.)

    13. Perform the inspection for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


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

    2. Using a 12 mm bi-hexagon wrench, remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.

    3. Push out the piston with connecting rod 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 such a way that they can be reinstalled to their original locations.

  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 such a way that they can be reinstalled to their original locations.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE


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      *a Protective Tape

      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 upper crankshaft thrust washers as a set. If necessary, replace the crankshaft.

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

      Tech Tips

      Tape the screwdriver tip before use.

  6. REMOVE CRANKSHAFT


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      *a No. 1 Crankshaft Bearing Cap
      *b No. 2 Crankshaft Bearing Cap

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

    2. Remove the 4 No. 1 crankshaft bearing caps and No. 2 crankshaft bearing cap from the cylinder block sub-assembly.

      Tech Tips


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

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

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

      Tech Tips

      Keep the No. 1 crankshaft bearings and upper crankshaft thrust washers together with the cylinder block sub-assembly.

    4. Check each crankshaft journals and crankshaft bearings for pitting and scratches.

      If a crankshaft bearing is damaged, replace it. If necessary, replace the crankshaft.

  7. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A01WYII

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  8. REMOVE CRANKSHAFT BEARING


    1. Remove the 5 No. 1 crankshaft bearings from the cylinder block sub-assembly.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    2. Remove the 5 No. 2 crankshaft bearings from the No. 1 crankshaft bearing caps and No. 2 crankshaft bearing cap.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  9. REMOVE PISTON RING SET


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

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  10. REMOVE PISTON PIN HOLE SNAP RING


    1. A01WYEXC03
      *a Protective Tape
      *b Front Mark

      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 is being 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.

  11. REMOVE PISTON


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

    2. A01WYMC

      Secure the piston in a vise between aluminum plates.

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

      Note

      Do not damage the piston.

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

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

      Tech Tips


      • When removing the piston pin, securely hold the connecting rod sub-assembly with to prevent it from falling.

      • The piston and piston pin are a matched set.

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  12. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01WXKO

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies.

      Note

      There are 2 different types of the No. 2 oil nozzle sub-assemblies arrange the removed parts in such a way that they can be reinstalled to their original locations.

  13. REMOVE STUD BOLT

    Note

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