CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A000XXX

      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 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 correct reassembly.

    2. A000Y6W

      Remove the 2 connecting rod cap bolts.

    3. A000VBU

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

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

    5. Clean the crank pin and bearing.

    6. A000YG7

      Lay a strip of Plastigage on the crank pin.

    7. A000XW9E04
      *1 Front
      *2 Front Mark

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

    8. A000XKQ

      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.

    9. A000YW5E06
      *1 Painted Mark
      *2 Front

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

    10. Tighten the cap bolts 90° as shown in the illustration.

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

      Note

      Do not turn the crankshaft.

    12. Remove the 2 connecting rod cap bolts.

    13. 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.

    14. Measure the Plastigage at its widest point.

      A000W3WE01
      Standard oil clearance
      0.025 to 0.050 mm (0.000984 to 0.00197 in.)
      Maximum oil clearance
      0.070 mm (0.00276 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 (2.20472 to 2.20496 in.)
        2 56.007 to 56.012 mm (2.20500 to 2.20520 in.)
        3 56.013 to 56.018 mm (2.20524 to 2.20543 in.)
        4 56.019 to 56.024 mm (2.20547 to 2.20567 in.)
        Crankshaft pin diameter
        Mark Thickness
        1 52.995 to 53.000 mm (2.08642 to 2.08661 in.)
        2 52.989 to 52.994 mm (2.08618 to 2.08638 in.)
        3 52.982 to 52.988 mm (2.08591 to 2.08614 in.)

    15. Completely remove the Plastigage.

    16. Perform the inspection above for each cylinder.

  3. REMOVE PISTON AND CONNECTING ROD


    1. A000UWJ

      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 and 8 connecting rods through the top of the cylinder block.

      Tech Tips


      • Keep the 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. A000ZU2

      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 0.00876 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. A000W21E03

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

    2. A000V0KE06

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

    3. Using a screwdriver, slightly pry up the 5 main bearing caps.

      A000V49E01
      *1 Protective Tape
      *2 Cylinder Block
      *3 Bearing Cap
      *4 Joint Surface

      Note


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

      • Pry up the left and right side of the cap little by little.

      Tech Tips

      Tape the screwdriver tip before use.

    4. Using 2 inside position crankshaft bearing cap bolts, loosen each crankshaft bearing cap by moving it forward and backward, and remove each crankshaft bearing cap.

    5. 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. A000Z7G

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

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A000UP6

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

  10. REMOVE PISTON RING SET

    A000WJ0

    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. A000WR6

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

      2. A000TK8

        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 the piston.


      1. A000TSC

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

      2. A000XGQ

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

      3. A000ZOQ

        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.