Engine Unit, Disassembly

ENGINE UNIT

COMPONENTS:

DISASSEMBLY

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new parts.

1. REMOVE TIMING BELT
a. Remove the timing belt
2. REMOVE CYLINDER HEAD
a. Remove the cylinder head

3. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
a. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.

4. REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
a. Remove the bolt and idler.

5. REMOVE CRANKSHAFT TIMING PULLEY
a. Using SST, remove the timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)

NOTICE: Do not turn the timing pulley.

6. REMOVE WATER PUMP ASSEMBLY
7. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
8. REMOVE OIL PAN BAFFLE PLATE
9. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY
10. REMOVE OIL STRAINER SUB-ASSEMBLY
11. REMOVE OIL PUMP ASSEMBLY

12. REMOVE REAR OIL SEAL RETAINER
a. Remove the 7 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
c. Remove the O-ring.
13. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the RH and LH drain unions.

14. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.290 mm (0.0063 to 0.0114 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
Standard connecting rod thickness: 22.880 to 22.920 mm (0.9008 to 0.9024 inch)
15. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE

a. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.

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

HINT: Keep the lower bearing inserted with the connecting rod cap.

d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

f. Lay a strip of Plastigage across the crank pin.

g. Install the connecting rod cap with the 2 bolts.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)

NOTICE: Do not turn the crankshaft. If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

h. Mark the front of the connecting cap bolt with paint.
i. Retighten the cap bolts 90° as shown.
j. Check that the painted mark is now at a 90° angle to the front.
k. Remove the 2 bolts, connecting rod cap and lower bearing.

l. Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 inch)
Maximum oil clearance: 0.059 mm (0.0023 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, and then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.

Standard Bearings:

EXAMPLE:
Connecting rod cap 3 + Crankshaft "1" = "4" (Use bearing "4")

Standard Connecting Rod Big End Inside Diameter:

Standard Sized Bearing Center Wall Thickness:

m. Completely remove the Plastigage.

16. REMOVE PISTON AND CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:
^ Keep the bearings, connecting rod and cap together.
^ Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

17. INSPECT CRANKSHAFT THRUST CLEARANCE
a. 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 (0.0008 to 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
Standard thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 inch)
18. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE

a. Uniformly loosen and remove the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

b. Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).

NOTICE: Be careful not to damage the cylinder block.

HINT:
^ Keep the lower bearing and crankshaft bearing cap together.
^ Be sure to arrange the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

c. Lift out the crankshaft.
d. Remove the 2 upper thrust washers.

HINT:
^ Be sure to arrange the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
^ Keep the upper bearings together with the cylinder block.

e. Clean each crankshaft journal and bearing.
f. Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
g. Place the crankshaft on the cylinder block.

h. Lay a strip of Plastigage across each journal.

i. Install the 5 crankshaft bearing caps in their proper locations.

HINT: If any one of the main bearing cap bolts is broken or deformed, replace it.

j. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.

k. Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

NOTICE: Do not turn the crankshaft.

If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt.

l. Mark the front of the crankshaft bearing cap bolts with paint.
m. Retighten the crankshaft bearing cap bolts by 90° in the order shown above.
n. Check that the painted mark is now at a 90° angle to the front.
o. Remove the crankshaft bearing caps.

p. Measure the Plastigage at its widest point.

Standard Clearance:

Maximum Clearance:

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer to the table for the appropriate bearing number. There are 5 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For other position bearings, use bearings marked 1, 2, 3, 4 and 5.

A = Cylinder block
B = Crankshaft

No. 1 And No. 5:

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5")

Others:

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3")

Standard Cylinder Block Crankshaft Journal Bore Diameter (A):

Standard Crankshaft Journal Diameter (B):

Standard Bearing Center Wall Thickness: No. 1 And No. 5:

Standard Bearing Center Wall Thickness: Others:

q. Remove the 5 upper crankshaft bearings from the cylinder block.

HINT: Be sure to arrange the bearing caps, bearings and thrust washers in such a way that they can be reinstalled exactly as before.

19. REMOVE PISTON SUB-ASSEMBLY WITH PIN

a. Check the piston and piston pin.
1 Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin with a new piston and pin set.

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

HINT: Be sure to arrange the removed piston rings in such a way that they can be reinstalled exactly as before.

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

d. Using a small screwdriver, pry out the 2 snap rings.

e. Gradually heat the piston to approximately 60°C (140°F).

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

HINT:
^ The piston and pin are a matched set.
^ Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.