CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. B003YPJ

      Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly 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 sub-assembly. If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. B003YMEC03
      *a Paint Mark

      Mark the connecting rod sub-assembly and the connecting rod cap with the corresponding cylinder numbers using paint.

      Tech Tips

      Mark the connecting rod sub-assembly and connecting rod cap for correct installation.

    2. B003Y9R

      Using a 14 mm bi-hexagon wrench, remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the lower bearing and connecting rod cap together.

    3. Clean the crank pin and connecting rod bearing.

    4. Check the crank pin and connecting rod bearing for pitting and scratches.

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

    5. B003XRAC03
      *1 Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. B003YNFC02
      *a Front Mark

      Check that the front mark on the connecting rod cap is facing forward, and then install the connecting rod cap on the connecting rod sub-assembly.

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

    8. B003Y9R

      Using a 14 mm bi-hexagon wrench, install and alternately tighten the connecting rod 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 during the measurement.

      If any of the connecting rod bolts does not meet the torque specification, replace the connecting rod bolt.

    9. B003Y66C01
      *a Paint Mark
      *b 90°
      B003XUN Engine Front Side

      Mark the front of each connecting rod bolt with paint.

    10. Tighten the connecting rod bolts 90° as shown in the illustration.

      Note

      Do not turn the crankshaft during the measurement.

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

      Tech Tips

      Keep the lower bearing and connecting rod cap together.

    12. B003YNJC03
      *1 Plastigage
      *a Number Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.033 to 0.063 mm (0.00130 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, replace the crankshaft.

      Tech Tips

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

      Standard Connecting Rod Diameter
      Item Specified Condition
      Mark 1

      54.500 to 54.508 mm

      (2.14567 to 2.14598 in.)
      Mark 2

      54.509 to 54.516 mm

      (2.14602 to 2.14629 in.)
      Mark 3

      54.517 to 54.524 mm

      (2.14633 to 2.14661 in.)
      Standard Bearing Center Wall Thickness (2013/04-2013/12)
      Item Specified Condition
      Mark 1

      1.483 to 1.487 mm

      (0.05839 to 0.05854 in.)
      Mark 2

      1.488 to 1.491 mm

      (0.05858 to 0.05870 in.)
      Mark 3

      1.492 to 1.495 mm

      (0.05874 to 0.05886 in.)
      Standard Bearing Center Wall Thickness (2014/01- )
      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.)
      Standard crank pin diameter
      51.492 to 51.500 mm (2.02724 to 2.02756 in.)

    13. Perform the inspection above for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


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

    2. Using a 14 mm bi-hexagon wrench, remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings (lower).

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

      Tech Tips


      • Keep the bearings, connecting rod sub-assembly and connecting rod cap together.

      • Arrange the piston and connecting rod sub-assembly in the correct order.

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the 8 connecting rod bearings from the connecting rod sub-assemblies and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. B003XZWC01
      *1 Protective Tape

      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 upper crankshaft thrust washers as a set. If necessary, replace the crankshaft.

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

      Tech Tips

      Tape the screwdriver tip before use.

  6. REMOVE CRANKSHAFT


    1. B003YP3C03
      *1 No. 1 Crankshaft Bearing Cap
      *2 No. 2 Crankshaft Bearing Cap

      Using a 14 mm bi-hexagon wrench, uniformly loosen the 10 crankshaft bearing cap set bolts in the sequence shown in the illustration. Remove the 10 crankshaft bearing cap set bolts.

    2. Remove the 4 No. 1 crankshaft bearing caps and No. 2 crankshaft bearing cap from the cylinder block sub-assembly.

      Tech Tips


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

      • Arrange the removed crankshaft bearing caps in the correct order.

    3. Remove the crankshaft from the cylinder block sub-assembly.

      Tech Tips

      Keep the crankshaft bearings and upper crankshaft thrust washers together with the cylinder block sub-assembly.

    4. Check each crankshaft journals and crankshaft bearings for pitting and scratches.

      If the crankshaft bearing is damaged, replace the it. If necessary, replace the crankshaft.

  7. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. B003Y37

      Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.

      Tech Tips

      Arrange the removed upper crankshaft thrust washers in the correct order.

  8. REMOVE CRANKSHAFT BEARING


    1. B003YJVC05
      *1 No. 1 Crankshaft Bearing
      *2 No. 2 Crankshaft Bearing
      *3 No. 1 Journal Bearing and No. 3 Journal Bearing
      *4 No. 2 Journal Bearing and No. 4 Journal Bearing and No. 5 Journal Bearing
      *5 No. 1 Journal Bearing and No. 5 Journal Bearing
      *6 No. 2 Journal Bearing and No. 3 Journal Bearing and No. 4 Journal Bearing
      *a Black
      *b Silver

      Remove the 5 No. 1 crankshaft bearings from the cylinder block sub-assembly.

      Tech Tips

      Arrange the No. 1 crankshaft bearings in the correct order.

    2. Remove the 5 No. 2 crankshaft bearings from the No. 1 crankshaft bearing caps and No. 2 crankshaft bearing cap.

      Tech Tips

      Arrange the No. 2 crankshaft bearings in the correct order.

  9. REMOVE PISTON RING SET


    1. B003XW3

      Type A


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

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

        Tech Tips

        Arrange the removed parts in the correct order.

    2. Type B


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

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

        Tech Tips

        Arrange the removed parts in the correct order.

  10. REMOVE PISTON PIN HOLE SNAP RING


    1. B003XY0C02
      *1 Protective Tape
      *a Front Mark

      Using a screwdriver, pry out the piston pin hole snap ring (front side).

      Note


      • Do not remove the snap ring (rear side) unless it has to be replaced.

      • Be careful not to damage the piston when removing the snap ring (rear side).

      Tech Tips

      Tape the screwdriver tip before use.

  11. REMOVE PISTON


    1. B003YPM

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

    2. Secure the piston between aluminum plates in a vise.

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

      Note

      Do not damage the piston.

    3. B003XTQ

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

      CAUTION:

      As the pistons are very hot, make sure to wear protective gloves when servicing.

      Tech Tips


      • When removing the piston pin, hold the connecting rod sub-assembly in place with your hand to prevent it from falling.

      • The piston and piston pin are a matched set.

      • Arrange the pistons, piston pins, piston rings, connecting rod sub-assemblies and connecting rod bearings in the correct order.

  12. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. B003YNVC01
      *1 15709-36010
      *2 15709-36020

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

      Note

      Since there are 2 different types of the No. 2 oil nozzle sub-assemblies, make sure to keep the parts in order of removal.

      Tech Tips

      Part Number Quantity
      15709-36010 3
      15709-36020 1

  13. REMOVE STUD BOLT

    Note

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