CYLINDER BLOCK DISASSEMBLY

REMOVE NO. 1 VENTILATION CASE

Tip:

There are 2 installation types for the No. 1 ventilation case.

Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.

Remove the 6 bolts and 2 nuts.

*a	Protective Tape

Using a screwdriver remove the ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly as shown in the illustration.

Note:

Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

Tip:

Tape the screwdriver tip before use.

INSPECT CONNECTING ROD THRUST CLEARANCE

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

Standard thrust clearance

0.160 to 0.342 mm (0.00630 to 0.0135 in.)

Maximum thrust clearance

0.342 mm (0.0135 in.)

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

INSPECT CONNECTING ROD OIL CLEARANCE

*a	Matchmark

Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

Tip:

The matchmarks on the connecting rods and caps are provided to ensure correct reassembly.

Using SST, uniformly loosen the 2 connecting rod bolts.

09205-16011
Using the 2 removed connecting rod bolts, remove the connecting rod cap and crankshaft bearing by wiggling the connecting rod cap back and foth.

Tip:
Keep the crankshaft bearing inserted in the connecting rod cap.
Clean the crank pin and connecting rod bearing.
Check the crank pin and connecting rod bearing for pitting and scratches.
If the crank pin or connecting rod bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

*a	Plastigage

Lay a strip of Plastigage on the crank pin.

*a	Front Mark

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

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

Note:
The connecting rod bolts should be tightened in 2 progressive steps.
Step 1:
1. Using SST, install and alternately tighten the connecting rod bolts of the connecting rod cap in several steps.
  
  09205-16011
  
  20 N*m
  
  204 kgf*cm
  
  15 ft.*lbf
  
  Note:
  Do not turn the crankshaft.

*a	Paint Mark
	Engine Front

Step 2:

Mark the front of the connecting rod bolts with paint.
Tighten the connecting rod bolts by 90° as shown in the illustration.

Note:
Do not turn the crankshaft.

Remove the 2 connecting rod bolts and connecting rod cap.

Tip:
Keep the crankshaft bearing inserted in the connecting rod cap.

*a	Plastigage
*b	1, 2 or 3 Mark

Measure the Plastigage at its widest point.

Standard oil clearance

0.014 to 0.038 mm (0.000551 to 0.00150 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, inspect the crankshaft.

Note:

Remove the Plastigage completely after the measurement.

Tip:

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

Standard Connecting Rod Large End Bore Diameter


Mark	Specified Condition
1	47.000 to 47.008 mm (1.85039 to 1.85070 in.)
2	47.009 to 47.016 mm (1.85074 to 1.85102 in.)
3	47.017 to 47.024 mm (1.85106 to 1.85133 in.)

Standard Connecting Rod Bearing Thickness


Mark	Specified Condition
1	1.489 to 1.493 mm (0.05862 to 0.05878 in.)
2	1.494 to 1.497 mm (0.05882 to 0.05894 in.)
3	1.498 to 1.501 mm (0.05898 to 0.05909 in.)

Standard crankshaft pin diameter

43.992 to 44.000 mm (1.7320 to 1.7323 in.)

Perform the inspection above for each cylinder.

REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

Using a ridge reamer,scrape off any carbon on the top of the cylinder.
Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block sub-assembly.
Tip:
- Keep the connecting rod bearing, connecting rod and connecting rod cap together.
- Arrange the pistons and connecting rods in the correct order.
- Be sure to arrange the removed pistons and connecting rods in such a way that they can be reinstalled exactly as before.

REMOVE CONNECTING ROD BEARING

Remove the connecting rod bearings.

Tip:
Arrange the removed parts in the correct order.

REMOVE PISTON RING SET

Using a piston ring expander, remove the 2 compression rings.
for 2-piece Type:
1. Remove the oil ring and oil ring expander by hand.
  
  Tip:
  Arrange the removed parts in the correct order.
for 3-piece Type:
1. Remove the oil ring expander, upper side rail and lower side rail by hand.
  
  Tip:
  Arrange the removed parts in the correct order.

REMOVE PISTON

Using a screwdriver, pry out the 2 piston pin hole snap rings.
Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).
Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
Tip:
- The piston and piston pin are a matched set.
- Arrange the pistons, piston pins, rings, connecting rods and connecting rod bearings in the correct order.

INSPECT CRANKSHAFT THRUST CLEARANCE

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

Standard thrust clearance

0.04 to 0.14 mm (0.00157 to 0.00551 in.)

Maximum thrust clearance

0.18 mm (0.00709 in.)

If the crankshaft thrust clearance is more than the maximum, replace the upper crankshaft thrust washers as a set. If necessary, replace the crankshaft.

Tip:
The thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 in.).

REMOVE CRANKSHAFT

Uniformly loosen and remove the 10 crankshaft bearing cap bolts in the sequence order shown in the illustration.
Using the 2 removed crankshaft bearing cap bolts, remove the 5 crankshaft bearing caps and 5 lower bearings.

Note:
Insert the crankshaft bearing cap bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block sub-assembly, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block sub-assembly.
Tip:
- Keep the crankshaft bearing and crankshaft bearing cap together as a set.
- Arrange the crankshaft bearing caps in the correct order.
Lift out the crankshaft.
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.

REMOVE UPPER CRANKSHAFT THRUST WASHER

Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.

REMOVE CRANKSHAFT BEARING

Remove the 5 crankshaft bearings from the cylinder block sub-assembly.

Tip:
Arrange the crankshaft bearings in the correct order.
Remove the 5 crankshaft bearings from the 5 crankshaft bearing caps.

Tip:
Arrange the removed parts in the correct order.

REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

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

CLEAN CYLINDER BLOCK

Note:

If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.