CYLINDER BLOCK DISASSEMBLY


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01DNUV

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

      Standard thrust clearance
      0.15 to 0.35 mm (0.00591 to 0.0138 in.)
      Maximum thrust clearance
      0.40 mm (0.0157 in.)

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE


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

      Tech Tips

      The matchmarks on the connecting rods and caps are for ensuring correct reassembly.

    2. A01DSJX

      Remove the 2 connecting rod cap bolts.

    3. 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 installed to the connecting rod cap.

    4. Clean the crank pin and bearing.

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

    6. A01DNW9E02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage on the crank pin.

    7. A01DTVWE02
      Text in Illustration
      *1 Front Mark

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

    8. Install the connecting rod cap Click here.

      Note

      Do not turn the crankshaft.

    9. A01DMQC

      Remove the 2 bolts and connecting rod cap (refer to the steps above).

    10. A01DPQ8E02
      Text in Illustration
      *1 Plastigage
      *2 4, 5 or 6 Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.039 to 0.066 mm (0.00154 to 0.00260 in.)
      Maximum oil clearance
      0.066 mm (0.00260 in.)

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

      If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. The standard thickness of each bearing is indicated by a 4, 5 or 6 mark on its surface.

      Standard crankshaft pin diameter
      52.989 to 53.002 mm (2.086 to 2.087 in.)
      Standard Bearing Center Wall Thickness
      Item Specified Condition
      Mark 4 1.484 to 1.487 mm (0.05843 to 0.05854 in.)
      Mark 5 1.488 to 1.490 mm (0.05858 to 0.05866 in.)
      Mark 6 1.491 to 1.493 mm (0.05870 to 0.05878 in.)

    11. Completely remove the Plastigage.

    12. Perform the inspection above for each crank pin.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01DO6IE06
      Text in Illustration
      *1 Ridge Reamer

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

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

      Tech Tips


      • Keep the bearing, connecting rod and cap together.

      • Arrange the piston and connecting rod assemblies 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. A01DSO9

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

      Standard thrust clearance
      0.02 to 0.22 mm (0.000787 to 0.00866 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

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

      Thrust washer thickness
      2.440 to 2.490 mm (0.0961 to 0.0980 in.)

  6. REMOVE CRANKSHAFT


    1. A01DO3EE01

      Uniformly loosen the 10 bearing cap bolts in several steps in the sequence shown in the illustration.

      Tech Tips


      • Keep the lower bearings and crankshaft bearing caps together.

      • Arrange the thrust washers in the correct order.

    2. Lift out the crankshaft to remove it.

    3. A01DQ98E01

      Remove the upper thrust washers from the cylinder block.

      Tech Tips

      Arrange the main bearing caps, bearings and thrust washers in the correct order.

  7. REMOVE CRANKSHAFT BEARING


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

      Tech Tips

      Arrange the removed parts in the correct order.

  8. REMOVE PISTON RING SET


    1. A01DNJL

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

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

    3. Remove the oil ring expander by hand.

      Tech Tips

      Arrange the piston rings in the correct order.

  9. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. Check the fitting condition between the piston and piston pin.


      1. Try to move the piston back and forth on the piston pin.

        If any movement is felt, replace the piston and pin as a set.

    2. Disconnect the connecting rod from the piston.


      1. A01DTFSE05
        Text in Illustration
        *1 Snap Ring

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

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

      3. A01DSQKE01

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

        Tech Tips


        • The piston and pin are a matched set.

        • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

  10. CLEAN PISTON WITH PIN SUB-ASSEMBLY


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

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

    3. Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  11. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01DUSCE01

      Using a 5 mm hexagon wrench, remove the oil nozzles.

  12. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A01DUAS

      Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.

      Standard thrust clearance
      0.07 to 0.13 mm (0.00276 to 0.00512 in.)
      Maximum thrust clearance
      0.20 mm (0.00787 in.)

      If the thrust clearance is more than the maximum, replace the balance shaft thrust washer. If necessary, replace the balance shaft.

  13. REMOVE NO. 1 BALANCE SHAFT


    1. A01DP8F

      Remove the bolt.

    2. A01DMIF

      Remove the balance shaft from the cylinder block.

      Note

      When removing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block.

  14. REMOVE NO. 1 BALANCE SHAFT DRIVEN GEAR


    1. A01DOP4E03
      Text in Illustration
      *1 No. 1 Balance Shaft Driven Gear
      *2 Sliding Key
      *3 Balance Shaft Thrust Washer
      *4 Balance Shaft Thrust Spacer

      Mount the head portion of the balance shaft in a vise.

      Note

      Do not damage the balance shaft.

    2. Remove the bolt.

    3. Remove the No. 1 balance shaft driven gear, sliding key, balance shaft thrust washer and balance shaft thrust spacer.

  15. REMOVE NO. 2 BALANCE SHAFT


    1. A01DTXF

      Remove the 2 bolts.

    2. A01DOR6

      Remove the balance shaft from the cylinder block.

      Note

      When removing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block.

  16. REMOVE NO. 2 BALANCE SHAFT DRIVEN GEAR


    1. A01DO13E03
      Text in Illustration
      *1 No. 2 Balance Shaft Driven Gear
      *2 No. 2 Balance Shaft Thrust Washer

      Mount the head portion of the balance shaft in a vise.

      Note

      Do not damage the balance shaft.

    2. Remove the bolt.

    3. Remove the No. 2 balance shaft driven gear and No. 2 balance shaft thrust washer.

  17. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01DTNGE01

      Remove the water drain cock sub-assembly from the cylinder block.

    2. Remove the water drain cock plug from the water drain cock sub-assembly.

  18. REMOVE STUD BOLT

    Note

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