Disassembly

DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND
2. REMOVE TIMING BELT AND PULLEYS
3. REMOVE CYLINDER HEAD
4. REMOVE RH ENGINE MOUNTING BRACKET
5. REMOVE LH ENGINE MOUNTING BRACKET
6. REMOVE STARTER
7. REMOVE KNOCK SENSORS
8. REMOVE ENGINE WIRE
a. Disconnect the crankshaft position sensor connector.





b. Remove the 2 bolts and engine wire cover from the LH side of the cylinder block.





c. Remove the 2 bolts, and disconnect the engine wire from the RH side of the cylinder block.
d. Remove the bolt and engine wire.
9. REMOVE WATER PUMP
10. REMOVE NO.2 OIL PAN
11. REMOVE OIL PAN BAFFLE PLATE
12. REMOVE NO.1 OIL PAN
13. REMOVE OIL STRAINER
14. REMOVE OIL PUMP





15. REMOVE WATER SEAL PLATE
Remove the 2 nuts and seal plate.
16. REMOVE ENGINE COOLANT DRAIN UNIONS
Remove the RH and LH drain unions.





17. 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 main bearing cap.
c. Remove the O-ring.





18. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth.
Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s).
If necessary, replace the crankshaft.
Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 inch)
19. 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 2 removed connecting rod cap 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 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.

NOTICE: Do not turn the crankshaft.

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





i. Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 - 0.047 mm (0.0008 - 0.0019 inch)
Maximum oil clearance: 0.065 mm (0.0026 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.








HINT: If using a standard bearing, replace it 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 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".





Reference
Connecting rod big end inside diameter





Crankshaft crank pin diameter





Standard sized bearing center wall thickness

j. Completely remove the Plastigage.





20. 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.

HINT:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in correct order.





21. 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: 2.440 - 2.490 mm (0.0961 - 0.0980 inch)
22. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE





a. Remove the 10 main bearing cap bolts.





b. Uniformly loosen and remove the 20 main bearing cap bolts in several passes, in the sequence shown.





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

NOTICE: Be careful not to damage the cylinder block.

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

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

HINT:
- Arrange the upper thrust washers in correct order.
- Keep the upper bearings together with the cylinder block.

f. Clean each main journal and bearing.
g. Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.





h. Install the 10 main bearings and 5 main bearing caps with the 30 bolts. Do not install the crankshaft.





i. Using a cylinder gauge, measure the inside diameter of the main bearing.
Bearing inside diameter: 66.986 - 67.000 mm (2.6372 - 2.6378 inch)
j. Measure the diameter of the main journal.
k. Subtract the main journal diameter measurement from the main bearing inside diameter measurement.





Standard clearance





Maximum clearance

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





HINT: If using a standard bearing, replace it 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 for the appropriate bearing number. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1","2", "3", "4" and "5".





No.1, No.5





Others








Reference
Cylinder block main journal bore diameter (A)





Crankshaft main journal diameter (B)

Standard bearing center wall thickness:





No.1 and No.5





Others





l. Remove the 10 bolts, 20 nuts, 5 main bearing caps and 5 lower main bearing. (See procedure a. to c.)
m. Remove the 5 upper main bearings from the cylinder block.

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





23. 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.





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

HINT: Arrange the piston rings in correct order only.

25. DISCONNECT CONNECTING ROD FROM PISTON





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





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





c. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and 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 correct order.