CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 VENTILATION CASE

    Tech Tips

    There are 2 installation methods for the No. 1 ventilation case. Depending on the installation method, the number of bolts, nuts and stud bolts used will vary.


    1. A01KCGS

      for Type A:

      Remove the 6 bolts and 2 nuts.

    2. A01KAQG

      for Type B:

      Remove the 8 bolts.

    3. A01QTRQC02
      *1 Protective Tape

      Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block with a screwdriver as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and No. 1 ventilation case.

      Tech Tips

      Tape the screwdriver tip before use.

  2. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01KCB5

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

      Standard thrust clearance
      0.160 to 0.342 mm (0.00630 to 0.0135 in.)
      Maximum thrust clearance
      0.342 mm (0.0135 in.)

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

  3. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01QPRZC02
      *1 Matchmark

      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 provided to ensure correct reassembly.

    2. A01QPAKN02

      Using SST, uniformly loosen and remove the 2 bolts.

      SST
      09205-16011
    3. A01KBW0

      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 in the connecting rod cap.

    4. Clean the crank pin and bearing.

    5. 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.

    6. A01QQZFC08
      *1 Plastigage

      Lay a strip of Plastigage on the crank pin.

    7. A01QOIFC03
      *1 Front Mark

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

    8. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.

    9. Install the connecting rod cap bolts.

      Note

      The connecting rod cap bolts should be tightened in 2 progressive steps.

    10. Step 1:


      1. A01QTQZE01

        Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps.

        SST
        09205-16011
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Note

        Do not turn the crankshaft.

    11. Step 2:


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

      2. Tighten the cap bolts 90°.

        Note

        Do not turn the crankshaft.

      3. Check that the paint marks are now at a 90° angle to the front.

    12. Remove the 2 bolts and connecting rod cap.

      Tech Tips

      Keep the lower bearing inserted in the connecting rod cap.

    13. A01QSBNC09
      *1 Plastigage
      *2 1, 2 or 3 Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.030 to 0.062 mm (0.00118 to 0.00244 in.)
      Maximum oil clearance
      0.070 mm (0.00276 in.)

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

      Note

      Remove the Plastigage completely after the measurement.

      Tech Tips

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

      Standard Connecting Rod Large End Bore Diameter
      Item Specified Condition
      Mark 1 50.000 to 50.008 mm (1.9685 to 1.9688 in.)
      Mark 2 50.008 to 50.016 mm (1.9688 to 1.9691 in.)
      Mark 3 50.016 to 50.024 mm (1.9691 to 1.9694 in.)
      Standard Connecting Rod Bearing Thickness
      Item Specified Condition
      Mark 1 1.489 to 1.493 mm (0.0586 to 0.0588 in.)
      Mark 2 1.493 to 1.497 mm (0.0588 to 0.0589 in.)
      Mark 3 1.497 to 1.501 mm (0.0589 to 0.0591 in.)
      Standard crankshaft pin diameter
      46.992 to 47.000 mm (1.8501 to 1.8504 in.)

    14. Perform the inspection above for each cylinder.

  4. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01KCQ9

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

    2. Push the piston, connecting rod 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.

      • Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

  5. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  6. REMOVE PISTON RING SET


    1. A01QOPAC02
      *1 Piston Ring Expander

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

    2. Remove the oil ring and oil ring expander by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE PISTON


    1. A01KDUE

      Using a screwdriver, pry out the 2 snap rings.

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

    3. A01KDGS

      Using a plastic-faced hammer and brass bar, 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.

  8. INSPECT CRANKSHAFT THRUST CLEARANCE


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

      Standard thrust clearance
      0.04 to 0.14 mm (0.00157 to 0.00551 in.)
      Maximum thrust clearance
      0.18 mm (0.00709 in.)

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

      Tech Tips

      The thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 in.).

  9. REMOVE CRANKSHAFT


    1. A01QS80N01

      Uniformly loosen and remove the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

    2. A01KD1L

      Use the removed crankshaft bearing cap bolts to remove the 5 crankshaft bearing caps and 5 lower bearings.

      Note

      Insert the bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

      Tech Tips


      • Keep each lower bearing and crankshaft bearing cap together as a set.

      • Arrange the crankshaft bearing caps in the correct order.

    3. Lift out the crankshaft.

    4. Check each crankshaft journal and bearing for pitting and scratches.

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

  10. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A01QPHG

      Remove the 2 upper crankshaft thrust washers from the cylinder block.

  11. REMOVE CRANKSHAFT BEARING


    1. A01KBI4

      Remove the 5 upper crankshaft bearings from the cylinder block.

      Tech Tips

      Arrange the bearings in the correct order.

    2. A01KB2R

      Remove the 5 lower crankshaft bearings from the 5 crankshaft bearing caps.

      Tech Tips

      Arrange the bearings in the correct order.

  12. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01KDI0

      Using a 5 mm socket hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzles.

  13. REMOVE NO. 1 TAPER SCREW PLUG


    1. A01KCML

      Remove the No. 1 taper screw plug.

  14. CLEAN CYLINDER BLOCK

    Note

    If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.

  15. REMOVE STUD BOLT

    Note

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