CYLINDER BLOCK DISASSEMBLY


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A015AZ3

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

      Standard thrust clearance
      0.14 to 0.54 mm (0.00551 to 0.0213 in.)
      Maximum thrust clearance
      0.60 mm (0.0236 in.)

      If the thrust clearance is more than the maximum, replace one or more connecting rods as necessary.

      If necessary, replace the crankshaft.

  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A0156HN

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

    2. Uniformly loosen the connecting rod bolts, and remove the connecting rod cap with bearing.

    3. Push out the piston and connecting rod with bearing through the top of the cylinder block.

      Tech Tips

      Arrange the piston and connecting rod assemblies in the correct order.

  3. REMOVE CONNECTING ROD BEARING


    1. A0158QX

      Remove the connecting rod and connecting rod cap bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  4. REMOVE PISTON RING SET


    1. A015CFM

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

    2. Using a piston ring expander, remove the oil ring.

    3. Remove the oil ring expander by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A0159ML

      Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

      If any movement is felt, replace the piston and pin as a set.

    2. A0156B7

      Using a screwdriver, pry out the 2 snap rings.

    3. A0159ZZE01

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

    4. A0155PO

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

      Tech Tips


      • The piston and pin are a matched set.

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

  6. CLEAN PISTON


    1. A015AL6

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

    2. A01595W

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

    3. A0156TM

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  7. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A0157JX

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

      Standard thrust clearance
      0.02 to 0.22 mm (0.000787 to 0.00866 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.

      Standard thrust washer thickness
      2.44 to 2.49 mm (0.0961 to 0.0980 in.)

      If necessary, replace the crankshaft.

  8. REMOVE CRANKSHAFT


    1. A015CHAE01

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

    2. A015C01E01

      Using several steps, loosen and remove the 20 crankshaft bearing cap set bolts uniformly in the sequence shown in the illustration.

    3. A015ATL

      Remove the 2 cylinder block stiffening plates.

    4. A015756

      Using 2 crankshaft bearing cap set bolts, pull out the 5 bearing caps.

      Note

      Take care not to damage the contact surfaces of the crankshaft bearing cap and cylinder block.

      Tech Tips


      • Keep the lower bearing and crankshaft bearing cap as a set.

      • Arrange the crankshaft bearing caps in the correct order.

    5. A0159NR

      Remove the crankshaft.

  9. REMOVE CRANKSHAFT THRUST WASHER SET

    A0158X8

  10. REMOVE CRANKSHAFT BEARING

    A015579E01

    Tech Tips


    • Keep the upper and lower crankshaft bearings and crankshaft bearing cap as a set.

    • Arrange the crankshaft bearing caps and bearings in the correct order.

  11. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A015APC

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

  12. INSPECT INPUT SHAFT BEARING (for Manual Transmission)


    1. Turn the bearing by hand.

      If the bearing is stuck or difficult to turn, replace the input shaft bearing. For removal procedures, refer to the following Click here and for installation procedures, refer to the following Click here.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.

  13. REMOVE CYLINDER BLOCK STRAIGHT SCREW PLUG


    1. A0156KCE01

      Remove the 2 straight screw plugs and 2 gaskets.