CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01HGDN

      Using a dial indicator, measure the thrust clearance while moving the connecting rod 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. If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01HE2YC02
      *a Paint Mark

      Place paint marks on the connecting rod and connecting rod cap to ensure correct reassembly.

    2. A01HENT

      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. A01HGPYC02
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. Install the connecting rod cap.

      Click here

      Note

      Do not turn the crankshaft.

    7. Remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    8. A01HFFBC02
      *a Plastigage
      *b Number Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.035 to 0.068 mm (0.00138 to 0.00268 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 that which is marked on the connecting rod. There are 3 sizes of standard 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 1.486 to 1.490 mm (0.0585 to 0.0587 in.)
      Mark 2 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
      Mark 3 1.495 to 1.498 mm (0.0589 to 0.0590 in.)

    9. Perform the inspection above for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


    1. A01HGWA

      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 lower connecting rod bearings.

    3. Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block sub-assembly.

      Tech Tips


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

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

      • Be sure to arrange the removed piston and connecting rod 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 rods and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01HH9Z

      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 0.24 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 crankshaft 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. A01HE8QN03

      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. A01HDSZ

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

  8. REMOVE CRANKSHAFT BEARING


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

      Tech Tips

      Arrange the crankshaft bearings in the correct order.

  9. REMOVE CRANKSHAFT PULLEY SET KEY


    1. Using a screwdriver, remove the 2 crankshaft pulley set keys from the crankshaft.

  10. REMOVE PISTON RING SET


    1. A01HF81C01
      *a Piston Ring Expander

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

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

      Tech Tips

      Arrange the removed parts in the correct order.

  11. REMOVE PISTON PIN HOLE SNAP RING


    1. A01HEY9C02
      *a Protective Tape

      Insert a small screwdriver into the service hole and pry out the piston pin hole snap ring on the front side.

      Note

      Do not remove the piston pin hole snap ring on the rear side unless it is necessary. When the piston pin hole snap ring needs to be removed, be careful not to damage the piston.

      Tech Tips

      Tape the screwdriver tip before use.

  12. REMOVE PISTON


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

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

      Tech Tips


      • The piston and piston pin are a matched set.

      • Be sure to arrange the removed pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in such a way that the parts can be reinstalled exactly as before.

      • Arrange the pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in the correct order.

  13. REMOVE OIL PIPE SUB-ASSEMBLY


    1. A01HDSDC02
      B008IUL Hexagon Socket Head Cap Bolt
      B008H52 Bolt

      Using a 5 mm hexagon wrench, remove the 4 hexagon socket head cap bolts.

    2. Remove the 3 bolts and oil pipe sub-assembly from the cylinder block sub-assembly.

    3. Remove the oil pipe gasket from the oil pipe sub-assembly.

  14. REMOVE STUD BOLT

    Note

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