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, 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
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, 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.
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
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.
Reference
Connecting rod big end inside diameter
Crankshaft crank pin diameter
Standard sized bearing 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.
NOTICE: Do not turn the crankshaft.
i. Remove the main bearing caps (See procedures a. and b.).
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 for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.
Standard size bearing selection chart
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.