CYLINDER BLOCK DISASSEMBLY


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01ENF8

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

      Standard thrust clearance
      0.15 to 0.55 mm (0.00591 to 0.0217 in.)
      Maximum thrust clearance
      0.70 mm (0.0276 in.)

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

      If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. Check that the front mark on the connecting rod and cap are aligned to ensure correct reassembly.

    2. A01EOHU

      Remove the 2 connecting rod cap bolts.

    3. A01EMUB

      Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower connecting rod bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower connecting rod bearing inserted to the connecting rod cap.

    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. Clean the crank pin and connecting rod bearing.

    6. A01EMVU

      Lay a strip of Plastigage on the crank pin.

    7. A01EQZJE01

      Place the connecting rod cap on the connecting rod with the front mark facing forward.

    8. A01EOQ1

      Install and alternately tighten the 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.

    9. A01ERLDE06

      Mark the front side of each connecting rod cap bolt with paint.

    10. Tighten the cap bolts 90° as shown in the illustration.

    11. Check that the painted marks are now at a 90° angle to the front.

      Note

      Do not turn the crankshaft.

    12. A01EOHU

      Remove the 2 connecting rod cap bolts.

    13. A01EMUB

      Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower connecting rod bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower connecting rod bearing inserted to the connecting rod cap.

    14. A01ES7LE02

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.025 to 0.050 mm (0.000984 to 0.00197 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, replace the crankshaft.

      Tech Tips


      • If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. The standard thickness of each bearing is indicated by a 1, 2, 3 or 4 mark on its surface.

      • Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin.

      Example:

      Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3")

      Reference:

      Standard Sized Bearing Center Wall Thickness
      Mark Thickness
      2 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
      3 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
      4 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
      5 1.498 to 1.501 mm (0.0590 to 0.0591 in.)
      6 1.501 to 1.504 mm (0.0591 to 0.0592 in.)
      7 1.504 to 1.507 mm (0.0592 to 0.0593 in.)
      Connecting Rod Big End Inside Diameter
      Mark Thickness
      1 59.000 to 59.006 mm (2.32283 to 2.32307 in.)
      2 59.006 to 59.012 mm (2.32307 to 2.32330 in.)
      3 59.012 to 59.018 mm (2.32330 to 2.32354 in.)
      4 59.018 to 59.024 mm (2.32354 to 2.32377 in.)
      Crankshaft Pin Diameter
      Mark Thickness
      1 55.994 to 56.000 mm (2.20448 to 2.20472 in.)
      2 55.988 to 55.994 mm (2.20425 to 2.20448 in.)
      3 55.982 to 55.988 mm (2.20401 to 2.20425 in.)

    15. Completely remove the Plastigage.

    16. Perform the inspection above for each cylinder.

  3. REMOVE PISTON AND CONNECTING ROD


    1. A01EPFWE01

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

    2. Remove the 16 cap bolts, 8 connecting rod caps and 8 lower connecting rod bearings.

    3. Push the 8 pistons and 8 connecting rods through the top of the cylinder block sub-assembly.

      Tech Tips


      • Keep the connecting rod bearing, connecting rod and connecting rod cap together.

      • Arrange the piston and connecting rods in the correct order.

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings from the connecting rods and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01EPFJ

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

      Standard thrust clearance
      0.020 to 0.220 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. If necessary, replace the crankshaft.

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

  6. REMOVE CRANKSHAFT


    1. A01ENVHE01

      Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps in the sequence shown in the illustration.

    2. A01EN22E01

      Uniformly loosen and remove the 20 bearing cap bolts in several steps in the sequence shown in the illustration.

    3. A01ERDGE04

      Using a screwdriver, slightly pry up the 5 main bearing caps.

      Tech Tips

      Tape the screwdriver tip before use.

      Note


      • Be careful not to damage the joint surface of the cylinder block sub-assembly and main bearing caps.

      • Pry up the left and right side of the cap little by little.

    4. Using the 2 inside position crankshaft bearing cap bolts, loosen each crankshaft bearing cap by moving it forward and backward, and remove each crankshaft bearing cap.

    5. Remove the crankshaft.

  7. REMOVE CRANKSHAFT BEARING


    1. Remove the crankshaft bearings from the crankshaft bearing caps and cylinder block sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  8. REMOVE CRANKSHAFT THRUST WASHER SET


    1. A01ENRL

      Remove the crankshaft thrust washer set from the cylinder block sub-assembly and No. 3 crankshaft bearing cap.

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01EOSF

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.

  10. REMOVE PISTON RING SET

    Tech Tips

    Arrange the piston rings in the correct order.


    1. A01EMVN

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

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

  11. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. Disconnect the connecting rod from the piston.


      1. A01EOU7

        Using a small screwdriver, pry off the 2 snap rings from the piston.

      2. A01EOMX

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

      3. A01ERPC

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

        Tech Tips


        • The piston and pin are a matched set.

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

    2. Clean the piston.


      1. A01ENPB

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

      2. A01ERMW

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

      3. A01EQKV

        Using solvent and a brush, thoroughly clean the piston.

        Note

        Do not use a wire brush.

  12. REMOVE STUD BOLT

    Note

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