Part 3
ENGINE UNITCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
DISASSEMBLY Continued
55. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push the piston, connecting rod and upper bearing through the top of the cylinder block.
HINT:
^ Keep the bearing, connecting rod and cap together.
^ Arrange the piston and connecting rod in the correct order.
56. REMOVE CONNECTING ROD BEARING
HINT: Arrange the removed parts in the correct order.
57. 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: 0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
Standard thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
58. REMOVE CRANKSHAFT AND CRANKSHAFT OIL CLEARANCE
(a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps, in the sequence shown in the illustration.
(b) Uniformly loosen the 16 bearing cap bolts in several steps, in the sequence shown in the illustration.
(c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.
NOTICE:
^ Pry up the main cap little by little to the right and left in turns.
^ Be careful not to damage the joint surface of the cylinder block and main bearing caps.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and scratches.
HINT: If the journal or bearing is damaged, replace the bearing.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Examine the front marks and numbers and install the bearing caps on the cylinder block.
HINT: A number is marked on each main bearing cap to indicate the installation position.
(i) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(j) Place the crankshaft bearing cap on the cylinder block.
(k) Install the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length: 100 to 102 mm (3.94 to 4.02 in.)
(l) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(m) Apply a light coat of engine oil on the threads and under the heads of the 8 main bearing cap bolts.
(n) Install the 8 main bearing cap bolts to the outside positions.
Bolt length:
HINT: The main bearing cap bolts are tightened in 2 progressive steps.
(o) Step 1
(1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
HINT: If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
NOTICE: Do not turn the crankshaft.
(p) Step 2
(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts by 90° as shown in the order shown in step 1.
(3) Check that the painted mark is now at a 90° angle to the front.
(q) Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
Bolt length:
45 mm (1.77 in.) for bolt A
30 mm (1.18 in.) for except bolt A
(r) Remove the 24 bolts and bearing cap bolts.
(s) Completely remove the Plastigage.
(t) If replacing a 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. 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.
Journal bearing:
EXAMPLE:
Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3")
Standard crankshaft main journal diameter:
Standard upper bearing center wall thickness No. 1 and No. 4 journal (Part 1):
Standard upper bearing center wall thickness No. 1 and No. 4 journal (Part 2):
No. 2 and No. 3 journal:
Standard lower bearing center wall thickness No. 1 and No. 4 journal:
No. 2 and No. 3 journal:
(u) Lift out the crankshaft.
(v) Remove the upper bearings and upper thrust washers from the cylinder block.
HINT: Arrange the bearings and thrust washers in the correct order.
59. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cocks from the cylinder block.
(b) Remove the water drain cock plugs from the water drain cocks.
60. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 3 oil nozzles.
(b) Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.
61. REMOVE PISTON RING SET
HINT: Arrange the piston rings in the correct order.
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Using a piston ring expander, remove the 2 side rails.
(c) Remove the oil ring expander by hand.
62. REMOVE PISTON WITH PIN SUB-ASSEMBLY
(a) Check the fitting condition between the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin.
HINT: If any movement is felt, replace the piston and pin as a set.
(b) Disconnect the connecting rod from the piston.
(1) Using a screwdriver, pry off the snap rings from the piston.
(2) Gradually heat the piston to approximately 80°C (176°F).
(3) Using a brass bar and plastic-faced hammer, 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.
(c) Clean piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
NOTICE: Do not use a wire brush.