Disassembly

DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
2. REMOVE GENERATOR
Remove the bolt, nut, pipe bracket and generator.
3. REMOVE TIMING BELT AND PULLEYS
4. REMOVE NO.2 WATER BYPASS PIPE WITH HOSE
Remove the bolt, 2 nuts, No.2 water bypass pipe and gasket.
5. REMOVE WATER PUMP
Remove the 6 bolts, water pump and O-ring.
6. REMOVE CYLINDER HEAD
7. REMOVE OIL PRESSURE SWITCH AND KNOCK SENSORS
Using SST, remove the switch and sensors.
SST 09816-30010
8. REMOVE OIL FILTER AND BRACKET ASSEMBLY
a. Remove the union bolt and oil filter bracket.
b. Remove the gasket from the union bolt.
c. Remove the O-ring from the oil filter bracket.
9. REMOVE NO.1 OIL PIPE
Remove the union bolt, No.1 oil pipe and 2 gaskets.
10. REMOVE FUEL INLET PIPE
Remove the 2 bolts and fuel inlet pipe.
11. REMOVE LH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
12. REMOVE RH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
13. REMOVE OIL PUMP





14. REMOVE REAR OIL SEAL RETAINER
a. Remove the 6 bolts of the retainer.
b. Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver.





15. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rods back and forth.
Standard thrust clearance: 0.250 - 0.402 mm (0.0098 - 0.0158 inch)
Maximum thrust clearance: 0.50 mm (0.0197 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
Connecting rod thickness: 25.898 - 25.950 mm (1.0196 - 1.0217 inch)
16. 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 connecting rod cap bolts.





c. Using the 2 removed connecting rod bolts, remove the connecting 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 bearings.
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: 1st 30 Nm (300 kgf.cm, 22 ft. lbs.) 2nd Turn extra 90°

NOTICE: Do not turn the crankshaft.

h. Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above)





i. Measure the Plastigage at its widest point.





Standard oil clearance:





Maximum oil clearance:
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 connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.





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





Connecting rod big end inside diameter:





Crankshaft crank pin diameter:





Standard sized bearing center wall thickness:
j. Completely remove the Plastigage.





17. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
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.
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in correct order.





18. 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 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 1.940 - 1.990 mm (0.0764 - 0.0783 inch)
19. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE





a. Uniformly loosen and remove the 14 main bearing cap bolts, in several passes, in the sequence shown.





b. Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.4 main bearing cap only).

HINT:
- Keep the lower bearing and main bearing cap together.
- Arrange the main bearing caps and lower thrust washers in correct order.

c. Lift out the crankshaft.

HINT: Keep the upper bearing 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 Plastigage across each journal.
h. Install the main bearing caps.
Torque:
1st 45 Nm (450 kgf.cm, 33 ft. lbs.)
2nd Turn extra 90°

NOTICE: Do not turn the crankshaft.

i. Remove the main bearing caps. (See procedures (a) and (b) above)





j. Measure the Plastigage at its widest point.





Standard clearance:





Maximum clearance:
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 refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

EXAMPLE: Cylinder block "3" (A) + Crankshaft "4" (B) = Total number 7 (Use bearing "3")





Standard sized bearing selection chart:
EXAMPLE: Cylinder block "3" Crankshaft "4" = Use bearing "3"
Reference





Cylinder block main journal bore diameter (A):





Crankshaft main journal diameter (B):





Standard bearing center wall thickness:
k. Completely remove the Plastigage.





20. REMOVE CRANKSHAFT
a. Lift out the crankshaft
b. Remove the upper bearings and upper thrust washers from the cylinder block.

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





21. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.





22. REMOVE PISTON RINGS
a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and oil ring expander by hand.

HINT: Arrange the piston rings in correct order only.

23. DISCONNECT CONNECTING ROD FROM PISTON





a. Using a small screwdriver, remove the 2 snap rings.
b. Gradually heat the piston to about 80°C (176°F).





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

HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

INSPECTION





1. CLEAN CYLINDER BLOCK
a. Remove gasket material
Using a gasket scraper, remove all the gasket material from the cylinder block surface.
b. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.





2. INSPECT CYLINDER BLOCK SURFACE FOR FLATNESS
Using precision straight edge and feeler gauge, measure the top surfaces of the cylinder block for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.





3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.





4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 86.000 - 86.013 mm (3.3858 - 3.3863 inch)
Maximum diameter: 86.02 mm (3.3866 inch)
If the diameter is greater than maximum, replace the cylinder block.





5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.





6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
Standard diameter: 9.96 - 9.97 mm (0.3921 - 0.3925 inch)
Minimum diameter: 9.7 mm (0.382 inch)
If the diameter is less than minimum, replace the bolt.
7. CLEAN PISTON





a. Using a gasket scraper, remove the carbon from the piston top.





b. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
c. Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.





8. INSPECT PISTON OIL CLEARANCE
a. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 34 mm (1.34 inch) from the piston head.
Piston diameter: 85.945 - 85.965 mm (3.3837 - 3.3844 inch)
b. Measure the cylinder bore diameter in the thrust directions. (See step 4)
c. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.035 - 0.068 mm (0.0014 - 0.0027 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)
If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.





9. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove.





Ring groove clearance:
If the clearance is not as specified, replace the piston.
10. INSPECT PISTON RING END GAP





a. Insert the piston ring into the cylinder bore.
b. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 inch) from the top of the cylinder block.





c. Using a feeler gauge, measure the ring end gap.





Standard ring end gap:





Maximum ring end gap:
If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.





11. INSPECT PISTON PIN FIT
At 80°C (176°F), you should be able to push the piston pin into the piston pin hole with your thumb.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a feeler gauge and rod aligner, check the connecting rod alignment.





- Check for out-of-alignment
Maximum out-of-alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If out-of-alignment is greater than maximum, replace the connecting rod assembly.





- Check for twist
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If twist is greater than maximum, replace the connecting rod assembly.
13. INSPECT PISTON PIN OIL CLEARANCE





a. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 inch)





b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 inch)
c. Subtract the piston pin diameter measurement from the bushing in side diameter measurement.
Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.





14. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the minimum diameter of the compressed bolt at the measuring point.
Standard diameter: 8.1 - 8.3 mm (0.319 - 0.327 inch)
Minimum diameter: 8.0 mm (0.315 inch)
If the diameter is less than minimum, replace the connecting rod bolt.





15. INSPECT CRANKSHAFT FOR RUNOUT
a. Place the crankshaft on V-blocks.
b. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than maximum, replace the crankshaft.
16. INSPECT MAIN JOURNALS AND CRANK PINS





a. Using a micrometer, measure the diameter of each main journal and crank pin.





Main journal diameter:





Crank pin diameter:
If the diameter is not as specified, check the oil clearance.
b. Check each main journal and crank pin for taper and out-of-round as shown.
Maximum taper and out-of round: 0.02 mm (0.0008 inch)
If the taper or out-of-round is greater than maximum, grind or replace the crankshaft.
17. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS
- Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 16).
- Install new main journal and/or crank pin undersized bearings.