CYLINDER BLOCK DISASSEMBLY


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A015ZBY

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

      Standard thrust clearance
      0.15 to 0.55 mm (0.00591 to 0.0217 in.)
      Maximum thrust clearance
      0.70 mm (0.0276 in.)

      If the thrust clearance is greater than the maximum, replace connecting rods as necessary.

      If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A015ZFNE01

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

      Note

      When installing the caps, the marks on bank 1 cylinders (1, 3, 5, 7) face towards the front of the engine and bank 2 cylinders (2, 4, 6, 8) face towards the rear of the engine.

    2. A0162UA

      Remove the 2 connecting rod cap bolts.

    3. A015Z2M

      Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

    4. Clean the crank pin and bearing.

      Note

      Check the crank pin and bearing for pitting and scratches.

    5. A0160TI

      Lay a strip of Plastigage on the crank pin.

    6. A0160ZNE02

      Check that the mark of the connecting rod cap is facing the correct direction.

      Note

      Be sure to assemble the bank 2 rods with the marks facing towards the rear of the engine.

    7. A0160VJ

      Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

      Note

      Do not turn the crankshaft.

    8. Mark the front side of each connecting cap bolt with paint.

    9. A01633HE06

      Retighten the cap bolts 90° as shown in the illustration.

    10. Check that the painted marks are now at a 90° angle to the front.

      Note

      Do not turn the crankshaft.

    11. Remove the 2 connecting rod cap bolts.

    12. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

    13. A01611XE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.037 to 0.062 mm (0.00146 to 0.00244 in.)
      Maximum oil clearance
      0.080 mm (0.00315 in.)

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

      Tech Tips


      • If replacing a connecting rod bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface.

      • Select the correct connecting rod bearing by adding together the number marks imprinted on the connecting rod big end and crank pin.

        Example:

        Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3")


      • Reference:

        Standard Sized Bearing Center Wall Thickness
        Mark Thickness
        2 1.483 to 1.486 mm (0.0584 to0.0585 in.)
        3 1.486 to 1.489 mm (0.0585 to 0.0586 in.)
        4 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
        5 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
        6 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
        7 1.498 to 1.501 mm (0.0590 to 0.0591 in.)
        Connecting Rod Big End Inside Diameter
        Mark Thickness
        1 56.000 to 56.006 mm (2.2047 to 2.2050 in.)
        2 56.007 to 56.012 mm (2.2050 to 2.2052 in.)
        3 56.013 to 56.018 mm (2.2052 to 2.2054 in.)
        4 56.019 to 56.024 mm (2.2055 to 2.2057 in.)
        Crankshaft Pin Diameter
        Mark Thickness
        1 52.995 to 53.000 mm (2.0864 to 2.0866 in.)
        2 52.989 to 52.994 mm (2.0862 to 2.0864 in.)
        3 52.982 to 52.988 mm (2.0859 to 2.0861 in.)

    14. Completely remove the Plastigage.

    15. Perform the inspection above for each cylinder.

  3. REMOVE PISTON AND CONNECTING ROD


    1. A015ZMB

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

    2. Remove the 16 cap bolts and 8 connecting rod caps.

    3. Push the 8 pistons, 8 connecting rods and 8 upper bearings through the top of the cylinder block.

      Tech Tips


      • Keep each bearing, connecting rod and cap together.

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

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the 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. A016172

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

      Standard thrust clearance
      0.020 to 0.220 mm (0.000787 to 0.00866 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

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

      Standard thrust washer thickness
      2.44 to 2.49 mm (0.0961 to 0.0980 in.)

  6. REMOVE CRANKSHAFT


    1. A0161HWE01

      Using several steps, uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in the sequence shown the illustration.

    2. A015ZHVE01

      Using several steps, uniformly loosen the 20 bearing cap bolts in the sequence shown in the illustration.

    3. A0161JKE01

      Using a screwdriver, pry out the main bearing caps. Remove the 5 main bearing caps and lower bearings.

      Note


      • Pry up the main beaning caps gradually and evenly in turns.

      • Be careful not to damage the joint surface between the cylinder block and main bearing caps.

      Tech Tips

      Tape the screwdriver tip before use.

    4. Remove the crankshaft.

  7. REMOVE CRANKSHAFT THRUST WASHER SET


    1. A015YON

      Remove the thrust washer set from the cylinder block and No. 3 bearing cap.

  8. REMOVE CRANKSHAFT BEARING


    1. Remove the crankshaft bearings from the bearing caps and cylinder block.

      Tech Tips

      Arrange the removed parts in the correct order.

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A015ZV9

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzle sub-assemblies.

  10. REMOVE PISTON RING SET

    Tech Tips

    Arrange the piston rings in the correct order.


    1. A015ZOM

      Using a piston ring expander, remove the 2 compression rings.

    2. Using a piston ring expander, remove the oil ring.

    3. Remove the oil ring expander by hand.

  11. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. Disconnect the connecting rod from the piston.


      1. A0160KU

        Using a screwdriver, pry off the piston pin hole snap rings from the piston.

      2. A015ZWQ

        Using a brass bar and plastic-faced hammer, 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.

    2. Clean the piston.


      1. A0161TK

        Using a gasket scraper, remove the carbon from the piston top.

      2. A0160Q4

        Using a groove cleaning tool or broken ring, clean the piston ring grooves.

      3. A01632D

        Using solvent and a brush, thoroughly clean the piston.

        Note

        Do not use a wire brush.