PROCEDURE
INSPECT CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the connecting rod thrust clearance while moving the connecting rod back and forth.
Standard connecting rod thrust clearance |
---|
0.14 to 0.54 mm (0.00551 to 0.0213 in.) |
Maximum connecting rod thrust clearance |
---|
0.60 mm (0.0236 in.) |
If the connecting rod thrust clearance is more than the maximum, replace one or more connecting rods as necessary.
If necessary, replace the crankshaft.
REMOVE PISTON WITH CONNECTING ROD
Using a ridge reamer, remove all the carbon from the top of the cylinder.
Uniformly loosen the connecting rod bolts, and remove the connecting rod cap with connecting rod bearing.
Push out the piston and connecting rod with connecting rod bearing through the top of the cylinder block sub-assembly.
Tech Tips
Arrange the piston and connecting rod assemblies in the correct order.
REMOVE CONNECTING ROD BEARING
Remove the connecting rod and connecting rod bearings.
Tech Tips
Arrange the removed parts in the correct order.
REMOVE PISTON RING SET
Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
Using a piston ring expander, remove the oil ring.
Remove the oil ring expander by hand.
Tech Tips
Arrange the removed parts in the correct order.
REMOVE PISTON WITH PISTON PIN
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 piston pin as a set.
Using a screwdriver, pry out the 2 piston pin hole snap rings.
Heat the piston to approximately 80°C (176°F).
Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
Tech Tips
The piston and piston pin are a matched set.
Arrange the piston and connecting rod assemblies in the correct order.
CLEAN PISTON
Using a gasket scraper, remove the carbon from the piston top.
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
Using solvent and a brush, thoroughly clean the piston.
Note
Do not use a wire brush.
INSPECT CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard crankshaft thrust clearance |
---|
0.02 to 0.22 mm (0.000787 to 0.00866 in.) |
Maximum crankshaft thrust clearance |
---|
0.30 mm (0.0118 in.) |
If the crankshaft thrust clearance is more than the maximum, replace the crankshaft 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.
REMOVE CRANKSHAFT
Using several steps, loosen and remove the 10 crankshaft bearing cap set bolts uniformly in the sequence shown in the illustration.
Using several steps, loosen and remove the 20 crankshaft bearing cap set bolts uniformly in the sequence shown in the illustration.
Remove the 2 cylinder block stiffening plates.
Using 2 crankshaft bearing cap set bolts, pull out the 5 crankshaft bearing caps.
Note
Take care not to damage the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.
Tech Tips
Keep the lower crankshaft bearing and crankshaft bearing cap as a set.
Arrange the crankshaft bearing caps in the correct order.
Remove the crankshaft.
REMOVE CRANKSHAFT THRUST WASHER SET
REMOVE CRANKSHAFT BEARING
*1 | Lower Crankshaft Bearing |
*2 | Upper Crankshaft Bearing |
Tech Tips
Keep the upper crankshaft bearing and lower crankshaft bearing and crankshaft bearing cap as a set.
Arrange the crankshaft bearing caps and crankshaft bearings in the correct order.
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.
REMOVE CYLINDER BLOCK STRAIGHT SCREW PLUG
*1 | Gasket |
*a | Front |
Remove the 2 cylinder block straight screw plugs and 2 gaskets.