CYLINDER BLOCK DISASSEMBLY

PROCEDURE

1. INSPECT CONNECTING ROD THRUST CLEARANCE

   
   

   1. 

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

      Standard connecting rod thrust clearance
      0.14 to 0.54 mm (0.00551 to 0.0213 in.)

      Maximum connecting rod thrust clearance
      0.60 mm (0.0236 in.)

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

      If necessary, replace the crankshaft.

2. REMOVE PISTON WITH CONNECTING ROD

   
   

   1. 

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

   2. Uniformly loosen the connecting rod bolts, and remove the connecting rod cap with connecting rod bearing.

   3. Push out the piston and connecting rod with connecting rod bearing through the top of the cylinder block sub-assembly.

      Tech Tips

      Arrange the piston and connecting rod assemblies in the correct order.

3. REMOVE CONNECTING ROD BEARING

   
   

   1. 

      Remove the connecting rod and connecting rod bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

4. REMOVE PISTON RING SET

   
   

   1. 

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

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

   3. Remove the oil ring expander by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

5. REMOVE PISTON WITH PISTON PIN

   
   

   1. 

      Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

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

   2. 

      Using a screwdriver, pry out the 2 piston pin hole snap rings.

   3. Heat the piston to approximately 80°C (176°F).

   4. 

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

      Tech Tips

      
      

      • The piston and piston pin are a matched set.

      • Arrange the piston and connecting rod assemblies in the correct order.

6. CLEAN PISTON

   
   

   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.

7. INSPECT CRANKSHAFT THRUST CLEARANCE

   
   

   1. 

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

      Standard crankshaft thrust clearance
      0.02 to 0.22 mm (0.000787 to 0.00866 in.)

      Maximum crankshaft thrust clearance
      0.30 mm (0.0118 in.)

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

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

      If necessary, replace the crankshaft.

8. REMOVE CRANKSHAFT

   
   

   1. 

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

   2. 

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

   3. 

      Remove the 2 cylinder block stiffening plates.

   4. 

      Using 2 crankshaft bearing cap set bolts, pull out the 5 crankshaft bearing caps.

      Note

      Take care not to damage the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.

      Tech Tips

      
      

      • Keep the lower crankshaft bearing and crankshaft bearing cap as a set.

      • Arrange the crankshaft bearing caps in the correct order.

   5. Remove the crankshaft.

9. REMOVE CRANKSHAFT THRUST WASHER SET

   

10. REMOVE CRANKSHAFT BEARING

    

    Text in Illustration

    *1	Lower Crankshaft Bearing
    *2	Upper Crankshaft Bearing

    Tech Tips

    
    

    • Keep the upper crankshaft bearing and lower crankshaft bearing and crankshaft bearing cap as a set.

    • Arrange the crankshaft bearing caps and crankshaft bearings in the correct order.

11. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

    
    

    1. 

       Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.

12. REMOVE CYLINDER BLOCK STRAIGHT SCREW PLUG

    
    
    1. 

       Text in Illustration

       *1	Gasket
       *a	Front

       Remove the 2 cylinder block straight screw plugs and 2 gaskets.