CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A001BMK

      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 (0.0059 to 0.0217 in.)
      Maximum thrust clearance
      0.70 mm (0.0276 in.)

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

      If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


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

    2. A001CT0

      Remove the 2 connecting rod cap bolts.

    3. A001CFC

      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. A001DT4E01
      *1 Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. A001BG4E05
      *1 Front
      *2 Front Mark

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

    7. A001AZU

      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. A0019TKE06
      *1 Painted Mark
      *2 Front

      Retighten the cap bolts by 90° as shown.

    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. Measure the Plastigage at its widest point.

      A0019M7E01
      Standard oil clearance
      0.025 to 0.050 mm (0.0010 to 0.0020 in.)
      Maximum oil clearance
      0.070 mm (0.0028 in.)

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

      Tech Tips


      • If replacing a 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 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 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
        3 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
        4 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
        5 1.498 to 1.501 mm (0.0590 to 0.0591 in.)
        6 1.501 to 1.504 mm (0.0591 to 0.0592 in.)
        7 1.504 to 1.507 mm (0.0592 to 0.0593 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 52.998 mm (2.0859 to 2.0865 in.)

    14. Completely remove the Plastigage.

    15. Perform the inspection above for each cylinder.

  3. REMOVE PISTON AND CONNECTING ROD


    1. A001FMS

      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 the bearing, connecting rod and cap together.

      • Arrange the piston and connecting rod 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. A0019V2

      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 (0.0008 to 0.0087 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. A001F3GE03

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

    2. A001EMRE05

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

    3. A001DAWE03
      *1 Protective Tape
      *2 Bearing Cap
      *3 Cylinder Block
      *4 Joint Surface

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note


      • Pry up the main cap little by little to the right and left in turns.

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

    4. Remove the crankshaft.

  7. 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.

  8. REMOVE CRANKSHAFT THRUST WASHER SET


    1. A001FQ2

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

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A001D6M

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

  10. REMOVE PISTON RING SET

    A001EJQ

    Tech Tips

    Arrange the piston rings in the correct order.


    1. 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. A001AB5

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

      2. A001CR9

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

      3. A001EF2

        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.

    2. Clean piston


      1. A001BGN

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

      2. A001EK9

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

      3. A001CF2

        Using solvent and a brush, thoroughly clean the piston.

        Note

        Do not use a wire brush.

  12. REMOVE STUD BOLT

    Note

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