CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01V9BB

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

      Standard thrust clearance
      0.160 to 0.512 mm (0.00630 to 0.0202 in.)
      Maximum thrust clearance
      0.512 mm (0.0202 in.)

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01V7AMC05
      *1 Alignment Mark

      Check the alignment marks on the connecting rod and cap to ensure correct reassembly.

    2. A01V9EM

      Remove the 2 bolts and connecting rod cap.

      Tech Tips

      Keep the lower bearing and connecting rod cap together.

    3. Clean the crank pin and bearing.

    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. A01VB3QC05
      *1 Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. Install the connecting rod cap.

      Click here

      Note

      Do not turn the crankshaft.

    7. Remove the 2 bolts and connecting rod cap.

      Tech Tips

      Keep the lower bearing and connecting rod cap together.

    8. A01V7FKC05
      *1 Plastigage
      *2 Number Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.033 to 0.063 mm (0.00113 to 0.00248 in.)
      Maximum oil clearance
      0.07 mm (0.00276 in.)

      Note

      Remove the Plastigage completely after the measurement.

      If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft.

      Tech Tips

      If replacing a bearing, select a new one with the same number as that which is marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

      Standard crank pin diameter
      51.492 to 51.500 mm (2.0272 to 2.0276 in.)
      Standard Connecting Rod Big End Inside Diameter
      Item Specified Condition
      Mark 1 54.500 to 54.508 mm (2.1457 to 2.1460 in.)
      Mark 2 54.509 to 54.516 mm (2.1460 to 2.1463 in.)
      Mark 3 54.517 to 54.524 mm (2.1463 to 2.1466 in.)
      Standard Size Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 1.486 to 1.490 mm (0.05850 to 0.05866 in.)
      Mark 2 1.491 to 1.494 mm (0.05870 to 0.05882 in.)
      Mark 3 1.495 to 1.498 mm (0.05886 to 0.05898 in.)

    9. Perform the inspection above for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


    1. A01V7ZX

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

    2. Remove the 8 bolts, 4 connecting rod caps and 4 lower bearings.

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

      Tech Tips


      • Keep the bearings, 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.

  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. A01VATI

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

      Standard thrust clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 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.

      Standard thrust washer thickness
      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

  6. REMOVE CRANKSHAFT


    1. A01V9Z5N06

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

    2. Remove the 5 bearing caps from the cylinder block.

      Tech Tips


      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.

      • Arrange the bearing caps in the correct order.

    3. Remove the crankshaft from the cylinder block.

      Tech Tips

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block.

    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.

  7. REMOVE CRANKSHAFT THRUST WASHER


    1. A01V782

      Remove the thrust washers from the cylinder block.

  8. REMOVE CRANKSHAFT BEARING


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

      Tech Tips

      Arrange the bearings in the correct order.

  9. REMOVE CRANKSHAFT PULLEY KEY


    1. Using a screwdriver, remove the 2 crankshaft pulley keys from the crankshaft.

  10. REMOVE PISTON RING SET


    1. A01V7O1C05
      *1 Piston Ring Expander

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

    2. for Type A:

      Remove the oil ring and oil ring expander by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

    3. for Type B:

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

      Tech Tips

      Arrange the removed parts in the correct order.

  11. REMOVE PISTON PIN HOLE SNAP RING


    1. A01V8TO

      Insert a small screwdriver into the service hole and pry out the snap ring on the front side.

      Note

      Do not remove the snap ring on the rear side unless it is necessary. When the snap ring heeds to be removed, be careful not to damage the piston.

  12. REMOVE PISTON


    1. Gradually heat the piston up to 80 to 90°C (176 to 194°F).

    2. A01V98M

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

      Tech Tips


      • The piston and pin are a matched set.

      • Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.

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

  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01V8S8

      Using a 5 mm hexagon wrench, remove the 2 bolts and 2 No. 1 oil nozzle sub-assemblies.

  14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01V810

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies.

  15. REMOVE STUD BOLT

    Note

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