CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. B003WCN

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

      Standard thrust clearance
      0.15 to 0.40 mm (0.00591 to 0.01575 in.)
      Maximum thrust clearance
      0.50 mm (0.0197 in.)

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

      Tech Tips

      The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.

    2. B003VIB

      Remove the 2 connecting rod cap bolts.

    3. B003T4F

      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.

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

    6. B003UCWC03
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    7. B003UWOC03
      *a Plastigage
      B003WAF Engine Front

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

    8. Install the connecting rod cap Click here.

      Note

      Do not turn the crankshaft.

    9. Remove the 2 connecting rod cap bolts and connecting rod cap.

    10. B003V0DC03
      *a Plastigage
      B003WJPC03
      *a Number Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.032 to 0.052 mm (0.00126 to 0.00205 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.

      Tech Tips

      If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing standard thickness is indicated by a number (1, 2, 3 or 4) marked on its surface.

      Standard Connecting Rod Diameter
      Mark Specified Condition
      1 56.000 to 56.006 mm (2.2047 to 2.2049 in.)
      2 56.006 to 56.012 mm (2.2049 to 2.2051 in.)
      3 56.012 to 56.018 mm (2.2051 to 2.2054 in.)
      4 56.018 to 56.024 mm (2.2054 to 2.2056 in.)
      Standard Connecting Rod Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.481 to 1.484 mm (0.0583 to 0.0584 in.)
      2 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
      3 1.487 to 1.490 mm (0.0585 to 0.0586 in.)
      4 1.490 to 1.493 mm (0.0586 to 0.0587 in.)
      Standard crankshaft pin diameter
      52.992 to 53.000 mm (2.0863 to 2.0866 in.)

      Note

      Completely remove the Plastigage after the measurement.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. B003W3JC03
      *a Ridge Reamer

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

    2. Push the piston, connecting rod assembly 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.

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings from the connecting rod sub-assemblies and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. REMOVE CRANKSHAFT


    1. B003X5IN03

      Uniformly loosen and remove the 8 crankshaft bearing cap bolts and 8 seal washers in several steps and in the sequence shown in the illustration.

    2. B003TSBE01

      Uniformly loosen the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. B003WZC

      Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

      Note


      • Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed.

      • Be careful not to damage the joint surfaces of the cylinder block and the crankshaft bearing cap.

    4. Remove the crankshaft.

  6. REMOVE CRANKSHAFT BEARING


    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET


    1. B003VX5

      Remove the crankshaft thrust washers from the cylinder block sub-assembly.

  8. REMOVE PISTON RING SET


    1. B003U4HC02
      *a Piston Ring Expander

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

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

      Tech Tips

      Arrange the removed parts in the correct order.

  9. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. B003WU4

      Disconnect the connecting rod from the piston.


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

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

      3. B003TW6

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

        Tech Tips


        • The piston and piston pin are a matched set.

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

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

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

    4. Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B003TAT

      Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies.

    2. Check the 3 No. 1 oil nozzles for damage or clogging.

      If necessary, replace the No. 1 oil nozzle sub-assembly.

  11. REMOVE CONNECTING ROD SMALL END BUSH


    1. B003WEHE01

      Using SST and a press, press out the connecting rod small end bush.

      SST
      09222-30010