Disassembly

PREPARATION FOR DISASSEMBLY
1. (M/T)
REMOVE CLUTCH COVER AND DISC
2. (M/T)
REMOVE FLYWHEEL
3. (A/T)
REMOVE DRIVE PLATE
4. REMOVE REAR END PLATE
Remove the bolt and end plate.
5. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
6. REMOVE DISTRIBUTOR
7. REMOVE TIMING BELT AND PULLEYS
B. REMOVE CYLINDER HEADS
9. REMOVE WATER PUMP
10. REMOVE OIL PAN AND OIL PUMP
11. REMOVE OIL FILTER AND FILTER BRACKET






12. REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch. SST 09816-30010






13. REMOVE COOLANT DRAIN COCK
(a) Remove the water drain hose.
(b) Remove the bolt and hose clamp.
(c) Remove the drain cock.






14. REMOVE WATER BY-PASS PIPE
(a) Disconnect the two knock sensor connectors.
(b) Remove the two bolts, nut and water by-pass pipe.






15. REMOVE KNOCK SENSORS
Using SST. remove the two knock sensors. SST 09816-30010






16. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the three bolts and idler pulley bracket.






CYLINDER BLOCK DISASSEMBLY
1. REMOVE REAR OIL SEAL RETAINER
Remove the six bolts and retainer.






2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.150 - 0.330 mm (0.0059 - 0.0130 in.)
Maximum thrust clearance: 0.38 mm (0.0150 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.






3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
(a) Using a punch or numbering stamp, mark the connecting rod and cap to ensure correct reassembly.






(b) Using SST, remove the connecting rod cap nuts. SST 09011-38121






(c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.

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






(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.






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






(g) Lay S strip of Plastigage across the crank pin.






(h) Install the connecting rod cap with the two nuts. (See step 6 at installation.
1st
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
2nd
Turn 90°

NOTICE: Do not turn the crankshaft.






(i) Remove the two nuts and connecting rod cap. (See procedure (b) and (c) above)






(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.028-0.065 mm (0.0011 - 0.0026 in.
U/S 0.25
0.027-0.080 mm (0.0011 - 0.0031 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.






HINT: If using a standard bearing, replace with one having the same number marked on the connecting rod cap. There are three sizes of standard bearings, marked "1", "2" and "3" accordingly.
(Reference)
Standard sized bearing center wall thickness:
Mark "1"
1.484 - 1.488 mm (0.0584 - 0.0586 in.)
Mark "2"
1.488 - 1.492 mm (0.0586 - 0.0587 in.)
Mark "3"
1.492 - 1.496 mm (0.0587 - 0.0589 in.)
(k) Completely remove the Plastigage.






4. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
(a) Using a ridge reamer, remove the all 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.
- Arrange the piston and connecting rod assembiies in correct order.






5. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 - 0.220 mm (0.0008 - 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness:
2.440 - 2.490 mm (0.0981 - 0.0980 in.)






6. REMOVE MAIN BEARING CAP AND CHECK OIL CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown.






(b) Using a screwdriver, pry up the main bearing cap, and remove the main bearing cap, lower main bearings and lower thrust washers (No.2 journal position of main bearing cap only).

HINT: Keep the lower main bearings and lower thrust washers together with the main bearing cap.

(c) Lift out the crankshaft.

HINT: Keep the upper main bearings and upper thrust washers together with the cylinder block.






(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged. replace the bearings.
If necessary, grind or replace the crankshaft.






(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastiga9e across each journal.






(h) Install the main bearing cap with the eight bolts. (See step 4 CyLINDER BLOCK ASSEMBLY.
1st
Torque: 1 N.m (625 kgf.cm, 45 ft.lbf)
2nd Turn 90°

NOTICE: Do not turn the crankshaft.






(i) Remove the eight bolts and main bearing cap. (See procedure (a) and (b) above)






(j) Measure the Plastigage at its widest poin Standard clearance:
STD
0.029 - 0.056 mm (0.0011 - 0.0022 in.)
U/S 0.25
0.028 - 0.080 mm (0.0011 - 0.0031 in.)
Maximum clearance:
0.08 mm (0.0031 in.)

HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be: 0.031 - 0.067 mm (0.0012 - 0.0026 in.). If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.






HINT: If using a standard bearing, replace with one having 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, then selecting the bearing with the same number as the total. There are five sizes of standard bearings, marked "1" "2", "3" "4" and "5", accordingly.






EXAMPLE: Cylinder block "2" + Crankshaft "1"= Total number 3 (Use bearing "3")
(Reference)
Cylinder block main journal bore diameter:
Mark "1": 68.010 - 68.016 mm (2.6776 - 2.6778 in.)
Mark "2": 68.016 - 68.022 mm (2.6778 - 2.6780 in.)
Mark "3": 68.022 - 68.028 mm (2.6780 - 2.6783 in.)
Crankshaft journal diameter:
Mark "0": 63.996 - 64.000 mm (2.5195 - 2.5197 in.)
Mark "1": 63.990 - 63.996 mm (2.5193 - 2.5195 in.)
Mark "2": 63.985 - 63.990 mm (2.5191 - 2.5193 in.)
Standard sized bearing center wall thickness:
Mark "1": 1.989 - 1.992 mm (0.0783 - 0.0784 in.)
Mark "2": 1.992 - 1.995 mm (0.0784 - 0.0785 in.)
Mark "3": 1.995 - 1.998 mm (0.0785 - 0.0787 in.)
Mark "4": 1.998 - 2.001 mm (0.0787 - 0.0788 in.)
Mark "5": 2.001 - 2.004 mm (0.0788 - 0.0789 in.)
(k) Completely remove the Plastigage.






7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust washers from cylinder block.

HINT: Arrange the main bearings and thrust washers in correct order.