Disassembly and Reassembly

CYLINDER BLOCK

COMPONENTS:

DISASSEMBLY





1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 to 0.30 mm (0.00591 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary. If necessary, replace the crankshaft.





2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Uniformly loosen the connecting rod bolts, and remove the connecting rod cap with bearing.
(c) Push out the piston with connecting rod 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 the correct order.

3. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearing.





4. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and oil ring (expander) by hand.





5. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a screwdriver, pry out the 2 snap rings.





6. REMOVE PISTON WITH PIN SUB-ASSEMBLY
(a) Gradually heat the piston to approximately 80°C (176°F).





(b) 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.





7. 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 (0.00157 to 0.00945 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.
Standard thrust washer thickness: 1.93 to 1.98 mm (0.0760 to 0.0780 in.)
If necessary, replace the crankshaft.





8. REMOVE CRANKSHAFT
(a) Using several steps, loosen and remove the 8 bearing cap bolts and seal washers uniformly in the sequence shown in the illustration.





(b) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence shown in the illustration.





(c) Using a screwdriver, pry out the bearing caps. Remove the 4 bearing caps and lower bearings.

NOTICE:
^ Push up on the cap little by little, alternating from the right and left side until the cap can be removed.
^ Be careful not to damage the joint surfaces of the cylinder block and the bearing cap.

9. REMOVE CRANKSHAFT THRUST WASHER SET
10. REMOVE CRANKSHAFT
11. REMOVE CRANKSHAFT BEARING





12. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 oil nozzles.

REASSEMBLY





1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon socket wrench, install the 3 oil nozzles with the 3 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)





2. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a screwdriver, install a new snap ring on one side of the piston pin hole.

HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.





3. INSTALL WITH PIN PISTON SUB-ASSEMBLY
(a) Gradually heat the piston to approximately 80°C (176°F).





(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

HINT: The piston and pin are a matched set.





(d) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.





4. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

5. INSTALL PISTON RING SET
(a) Install the oil ring (expander) and 2 side rails by hand.





(b) Using a piston ring expander, install the 2 compression rings.

NOTICE: Install the No. 2 compression ring with the painted mark on the right side.





(c) Position the piston rings so that the ring ends are as shown.





6. INSTALL CONNECTING ROD BEARING
(a) Install the bearing to the connecting rod cap.

NOTICE:
^ Clean the contact surface of the bearing and connecting rod cap.
^ Do not apply engine oil to the bearing and its contact surface.





(b) Install the bearing to the connecting rod.

NOTICE:
^ Clean the contact surface of the bearing and connecting rod.
^ Do not apply engine oil to the bearing and its contact surface.





7. INSTALL CRANKSHAFT BEARING

HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean each main journal and bearing.





(b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

NOTICE:
^ Clean the contact surface of the bearing and cylinder block.
^ Do not apply engine oil to the bearing and its contact surface.





(c) Align the bearing claw with the claw groove of the bearing cap, and push in the 4 lower bearings.

NOTICE:
^ Clean the contact surface of the bearing and crankshaft bearing cap.
^ Do not apply engine oil to the bearing and its contact surface.

HINT: The number marked on each bearing cap indicates the installation position.

8. INSTALL CRANKSHAFT

NOTICE: Clean the contact surface of each main journal and crank pin.

(a) Apply new engine oil to the upper bearing and install the crankshaft on the cylinder block.





(b) Push the crankshaft toward the rear thrust direction to create clearance, and install a thrust washer to the No. 2 journal position with the oil groove facing the front of the engine.
(c) Push the crankshaft toward the forward thrust direction to create clearance, and install a thrust washer to the No. 2 journal position with the oil groove facing the rear of the engine.





(d) Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward.





(e) Examine the front marks and numbers and install the bearing caps on the cylinder block.
(f) Apply a light coat of engine oil to the threads of the bearing cap bolts.
(g) Temporarily install the 8 bearing cap bolts to the inside positions.





(h) Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.236 in.).





(i) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(j) Apply a light coat of engine oil to the threads of the bearing cap bolts.





(k) Step 1:
(1) Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)





(l) Step 2:
(1) Mark the front side of the bearing cap bolts with paint.
(2) Tighten the bearing cap bolts another 90° in the sequence as shown.
(m) Check that the painted marks are now at a 90° angle to the front.
(n) Check that the crankshaft turns smoothly.





(o) Using several steps, install the 8 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 26 N*m (262 kgf*cm, 19 ft.*lbf)
(p) Check that the crankshaft turns smoothly.
9. INSPECT CRANKSHAFT THRUST CLEARANCE
10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.





(b) Check the positions of the piston ring ends.





(c) Using a hammer handle and piston ring compressor, press a piston and connecting rod assembly into each cylinder with the front mark of the piston facing forward.





(d) Check that the protrusion of the connecting rod cap is facing the correct direction.

NOTICE: Match the numbered connecting rod cap with the connecting rod.

(e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.





(f) Step 1:
(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(g) Step 2:
(1) Mark the front side of each connecting rod cap bolt with paint.





(2) Tighten the cap bolts in step 1 another 90°.
(h) Check that the painted marks are now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
11. INSPECT CONNECTING ROD THRUST CLEARANCE