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CYLINDER BLOCK DISASSEMBLY

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PROCEDURE


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    INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A0004MU

      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.

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    INSPECT CONNECTING ROD OIL CLEARANCE


    1. A00043PE03

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

      Table 1. Text in Illustration
      *a Alignment Mark
    2. A0009K4

      Remove the 2 connecting rod bolts and connecting rod cap.

      Tip:

      Keep the connecting rod 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. A00055SE01

      Lay a strip of Plastigage on the crank pin.

      Table 2. Text in Illustration
      *1 Plastigage
    6. A0006U6E01

      Check that the front mark of the connecting rod cap is facing in the correct direction.

      Table 3. Text in Illustration
      *1 Front Mark
    7. A0009K4

      Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

    8. Install and alternately tighten the 2 connecting rod bolts of the connecting rod cap in several steps.

      40 N*m 408 kgf*cm 30 ft.*lbf
      Note:

      Do not turn the crankshaft during the measurement.

    9. A0006J4E20

      Mark the front of each connecting rod bolt with paint.

      Table 4. Text in Illustration
      *1 Paint Mark
      A0009JS Engine Front

    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.

      Tip:

      Keep the connecting rod bearing and connecting rod cap together.

    12. A0007K0E01

      Measure the Plastigage at its widest point.

      Table 5. Text in Illustration
      *1 Plastigage
      *2 Number Mark
      Standard oil clearance
      0.030 to 0.063 mm (0.00118 to 0.00248 in.) or 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, grind or replace the crankshaft.

      Tip:

      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 connecting rod 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 Connecting Rod Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 1.486 to 1.490 mm (0.0585 to 0.0587 in.)
      Mark 2 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
      Mark 3 1.495 to 1.498 mm (0.0589 to 0.0590 in.)

    13. Perform the inspection above for each cylinder.

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    REMOVE PISTON WITH CONNECTING ROD


    1. A000784

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

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

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

      Tip:

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

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

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

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    REMOVE CONNECTING ROD BEARING


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

      Tip:

      Arrange the removed parts in the correct order.

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    INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A00099B

      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.)
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    REMOVE CRANKSHAFT


    1. A00065DE07

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

    2. Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

      Tip:

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

      • Arrange the crankshaft bearing caps in the correct order.

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

      Tip:

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

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

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

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    REMOVE CRANKSHAFT THRUST WASHER


    1. A0008CC

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

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    REMOVE CRANKSHAFT BEARING


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

      Tip:

      Arrange the bearings in the correct order.

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    REMOVE CRANKSHAFT PULLEY KEY


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

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    REMOVE PISTON RING SET

    Tip:

    Type A and type B can be distinguished by the mark on the piston and the shape of the oil ring.

    Table 6. Text in Illustration
    *A Type A *B Type B
    *1 Piston *2 Oil Ring

    1. A0007KUE02

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

      Table 7. Text in Illustration
      *1 Piston Ring Expander

    2. Type A:


      1. Remove the oil ring and expander by hand.

        Tip:

        Arrange the removed parts in the correct order.

    3. Type B:


      1. Remove the oil ring expander, upper oil ring side rail and lower oil ring side rail by hand.

        Tip:

        Arrange the removed parts in the correct order.

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    REMOVE PISTON PIN HOLE SNAP RING


    1. A0006IRE03

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

      Table 8. Text in Illustration
      *1 Protective Tape
      *a Front Mark
      Note:

      Do not remove the snap ring (rear side) unless necessary.

      Tip:

      Tape the screwdriver tip before use.

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    REMOVE PISTON


    1. A00072B

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

    2. A0004GV

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

      Tip:

      • The piston and piston pin are a matched set.

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

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

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    REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A0007QV

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

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    REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A0003UQ

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

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    REMOVE STUD BOLT

    Note:

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


    1. A00066W

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts.