CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01V0HM

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

      Standard thrust clearance
      0.16 to 0.36 mm (0.00630 to 0.0142 in.)
      Maximum thrust clearance
      0.36 mm (0.0142 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. Mark each cylinder No. on the connecting rod and connecting rod cap with paint.

    2. A01UZE1E02

      Using SST, remove the 2 connecting rod cap bolts.

      SST
      09205-16010
    3. A01UZYB

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

    4. Clean the crank pin and connecting rod bearing.

      Note

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

    5. A01UXMLE03
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across the crank pin.

    6. A01V0X7E02
      Text in Illustration
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing forward and install the connecting rod cap.

    7. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

    8. Step 1:


      1. A01UZ2OE04

        Using SST, install and alternately tighten the connecting rod cap bolts of the connecting rod cap in several steps.

        Note

        Do not turn crankshaft.

        Torque:
        15 N*m  { 153 kgf*cm, 11 ft.*lbf }
        SST
        09205-16010

    9. Step 2:


      1. A01UY6IE39
        Text in Illustration
        *a Paint Mark
        A01UY2W Engine Front

        Mark each connecting rod cap bolts head with a paint mark as shown in the illustration.

        Note

        Do not turn crankshaft.

      2. Tighten the connecting rod cap bolts 90° in the sequence shown in step 1.

    10. Remove the connecting rod cap.

    11. A01V0LME03
      Text in Illustration
      *1 Plastigage

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.012 to 0.038 mm (0.000472 to 0.00150 in.)
      Maximum oil clearance
      0.06 mm (0.00236 in.)

      Note

      Completely remove the Plastigage.

    12. A01V26YE03
      Text in Illustration
      *a Number Mark
      *b Front Mark

      If the oil clearance is greater than the maximum, select and replace the connecting rod bearings. If necessary, use an undersized bearing.

      Reference
      Number Mark Connecting Rod External Diameter Center Bearing Thickness Oil Clearance
      1 43.000 to 43.008 mm (1.6929 to 1.6932 in.) 1.488 to 1.492 mm (0.058583 to 0.058740 in.) 0.012 to 0.038 mm (0.000472 to 0.00150 in.)
      2 43.008 to 43.016 mm (1.6932 to 1.6935 in.) 1.492 to 1.496 mm (0.058740 to 0.058898 in.) 0.012 to 0.038 mm (0.000472 to 0.00150 in.)
      3 43.016 to 43.024 mm (1.6935 to 1.6939 in.) 1.496 to 1.500 mm (0.058898 to 0.059055 in.) 0.012 to 0.038 mm (0.000472 to 0.00150 in.)
      U/S 0.25 43.000 to 43.024 mm (1.6929 to 1.6939 in.) 1.610 to 1.614 mm (0.063386 to 0.063543 in.) 0.013 to 0.059 mm (0.000512 to 0.00232 in.)

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01UXT3

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

    2. Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block.

      Tech Tips


      • Keep each connecting rod bearing, connecting rod and connecting rod cap as a set.

      • Arrange the removed parts in the correct order.

  4. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01UYLP

      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
      0.3 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

      Reference
      Item Thrust Washer Thickness Thrust Clearance
      STD 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      O/S 0.125 2.493 to 2.543 (0.0981 to 0.100 in.) 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      O/S 0.250 2.555 to 2.605 (0.101 to 0.103 in.) 0.04 to 0.24 mm (0.00157 to 0.00945 in.)

  5. REMOVE CONNECTING ROD BEARING


    1. Remove the 8 connecting rod bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  6. REMOVE PISTON RING SET


    1. A01V0GI

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

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

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE PISTON SUB-ASSEMBLY WITH PISTON PIN


    1. A01V1DEE01

      Using SST, press out the piston pin from the piston.

      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00061, 09221-00090, 09221-00100 )

      Tech Tips


      • The piston and pin are a matched set.

      • Arrange the removed parts in the correct order.

  8. REMOVE CRANKSHAFT


    1. A01UYB4E03

      Using several steps, uniformly loosen and remove the 10 crankshaft bearing cap bolts with a 12 mm socket wrench for 12 pointed head in the sequence shown in the illustration.

    2. A01UY2Z

      Using the 2 removed crankshaft bearing cap bolts, remove the 5 crankshaft bearing caps.

      Tech Tips


      • Keep each No. 2 crankshaft bearing and crankshaft bearing cap as a set.

      • Arrange the removed parts in the correct order.

    3. A01V07B

      Remove the crankshaft from the cylinder block.

  9. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A01UXTN

      Remove the 2 upper crankshaft thrust washers from the cylinder block.

      Tech Tips

      Arrange the removed parts in the correct order.

  10. REMOVE CRANKSHAFT BEARING


    1. A01UZ28

      Remove the 5 upper crankshaft bearings from the cylinder block.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. A01UZG7

      Remove the 5 lower crankshaft bearings from the crankshaft bearing cap.

      Tech Tips

      Arrange the removed parts in the correct order.

  11. REMOVE WATER BY-PASS HOSE UNION


    1. A01UY88

      Using a 17 mm deep socket wrench, remove the water by-pass hose union from the cylinder block.

  12. REMOVE OIL JET


    1. A01V0VW

      Remove the oil jet from the cylinder block.