CYLINDER BLOCK DISASSEMBLY


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01G7Y7

      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. A01G6RDE01
      Text in Illustration
      *a Alignment Mark

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

    2. A01G48F

      Remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      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. A01G5IEE01
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. A01G9B3E01
      Text in Illustration
      *1 Front Mark

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

    7. A01G48F

      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.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

      Do not turn the crankshaft during the measurement.

    9. A01G6MOE20
      Text in Illustration
      *1 Paint Mark
      A01G47H Engine Front

      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 connecting rod bearing and connecting rod cap together.

    12. A01G5HTE01
      Text in Illustration
      *1 Plastigage
      *2 Number Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.030 to 0.063 mm (0.00118 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 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 Bearing Center Wall Thickness
      Item Specified Condition
      Mark 1 1.483 to 1.487 mm (0.0584 to 0.0585 in.)
      Mark 2 1.488 to 1.491 mm (0.0586 to 0.0587 in.)
      Mark 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.)

    13. Perform the inspection above for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


    1. A01G9AN

      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.

      Tech Tips


      • 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.

  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. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01G47P

      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. A01G9KXE01

      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.

      Tech Tips


      • 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.

      Tech Tips

      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.

  7. REMOVE CRANKSHAFT THRUST WASHER


    1. A01G70L

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

  8. REMOVE CRANKSHAFT BEARING


    1. Remove the crankshaft bearings and No. 2 crankshaft bearings from the cylinder block sub-assembly and crankshaft 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. A01G5D9E02
      Text in Illustration
      *1 Piston Ring Expander

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

    2. Remove the oil ring and expander by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

  11. REMOVE PISTON PIN HOLE SNAP RING


    1. A01G60CE03
      Text in Illustration
      *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 necessary.

      Tech Tips

      Tape the screwdriver tip before use.

  12. REMOVE PISTON


    1. A01G4LG

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

    2. A01G8QZ

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

      Tech Tips


      • 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.

  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01G4VD

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

  14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01G5OW

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

  15. REMOVE STUD BOLT

    Note

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