Disassembly and Reassembly

CYLINDER BLOCK

COMPONENTS (Part 1):

COMPONENTS (Part 2):

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: 0.160 to 0.290 mm (0.00629 to 0.0114 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly.
If necessary, replace the crankshaft.
Standard connecting rod thickness: 22.880 to 22.920 mm (0.901 to 0.902 in.)

2. INSPECT CONNECTING ROD 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 and connecting rod cap together.

(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.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)

NOTICE: Do not turn the crankshaft.

If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

(h) Mark the front side of each connecting rod cap bolt with paint.
(i) Tighten the cap bolts another 90° as shown.
(j) Check that the painted marks are now at a 90° angle to the front.
(k) Remove the 2 bolts, connecting rod cap and lower bearing.

(l) Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 to 0.047 mm (0.000827 to 0.00185 in.)
Maximum oil clearance: 0.059 mm (0.00232 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT:
If replacing a standard bearing, replace it with one that has 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 select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.

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

Standard Bearing Chart:

Standard connecting rod big end inside diameter:

Standard crankshaft crank pin diameter:

Standard sized bearing center wall thickness:

(m) Completely remove the Plastigage.
(n) Perform the inspection above for each cylinder.

3. REMOVE PISTON AND CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Remove the 16 cap bolts and 8 connecting rod caps.
(c) 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 in the correct order.
^ Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

4. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearings from the connecting rods and connecting rod caps.

HINT: Arrange the removed parts in the correct order.

5. 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: 0.020 to 0.220 mm (0.000787 to 0.00866 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: 2.440 to 2.490 mm (0.0961 to 0.0980 in.)

6. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Uniformly loosen and remove the 10 crankshaft bearing cap bolts in the sequence shown in the illustration.

(b) Using 2 screwdrivers, gradually pry up and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap.

HINT:
^ Keep the lower bearing and crankshaft bearing cap together.
^ Arrange the removed parts in the correct order.
^ Be sure to arrange the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

(c) Lift out the crankshaft.
(d) Remove the 2 upper thrust washers.

HINT:
^ Be sure to arrange the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
^ Keep the upper bearings together with the cylinder block.

(e) Clean each crankshaft journal and bearing.
(f) Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
(g) Place the crankshaft on the cylinder block.

(h) Lay a strip of Plastigage across each journal.

(i) Examine the front marks and number, and install the 5 crankshaft bearing caps to the cylinder block.

HINT:
^ A number is marked on each bearing cap to indicate the installation position.
^ If any one of the main bearing cap bolts is broken or deformed, replace it.

(j) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.

(k) Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

NOTICE: Do not turn the crankshaft.

If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt.

(l) Mark the front of the crankshaft bearing cap bolts with paint.
(m) Tighten the crankshaft bearing cap bolts another 90° in the order shown above.
(n) Check that the painted marks are now at a 90° angle to the front.
(o) Remove the crankshaft bearing caps and bolts.

(p) Measure the Plastigage at its widest point.

Standard oil clearance:

Maximum oil clearance: 0.065 mm (0.00256 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If replacing a standard bearing, replace it with one that has 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. For No. 1 and No. 5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For other position bearings, use bearings marked 1, 2, 3, 4 and 5.

A = Cylinder block number mark
B = Crankshaft number mark

EXAMPLE:
No. 1 and No. 5 journal
Cylinder block "7" + Crankshaft "6" = Total number 13 (Use upper bearing "4" and lower bearing "5") Other journal
Cylinder block "7" + Crankshaft "6" = Total number 13 (Use upper bearing "2" and lower bearing "3")

HINT: (Cylinder block journal diameter - crankshaft journal diameter - 5) X 1000 = A + B

No. 1 and No. 5 journal:

Other journal:

Standard cylinder block crankshaft journal bore diameter (A) (Part 1):

Standard cylinder block crankshaft journal bore diameter (A) (Part 2):

Standard crankshaft journal diameter (B):

Standard bearing center wall thickness: No. 1 and No. 5:

Standard bearing center wall thickness: Other:

(q) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the crankshaft bearings and upper thrust washers from the cylinder block.

HINT: Arrange the bearings and thrust washers in the correct order.

8. REMOVE PISTON RING SET

HINT: Arrange the piston rings in the correct order.

(a) Using a piston ring expander, remove the No. 1 and No. 2 piston rings.
(b) Remove the oil ring (2 side rails and expander) by hand.

9. REMOVE PISTON SUB-ASSEMBLY WITH PIN
(a) Check the fitting condition between the piston and piston pin.
(1) Move the connecting rod back and forth on the piston pin. Check the fitting condition.
If abnormal movement is felt, replace the piston and pin as a set.
(2) Rotate the piston back and forth on the piston pin. Check the fitting condition.
If abnormal movement is felt, replace the piston and pin as a set.

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

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

HINT:
^ The piston and pin are a matched set.
^ Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.

10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

REASSEMBLY
1. INSTALL STUD BOLT

NOTICE: If a stud bolt is deformed or the threads are damaged, replace it.

(a) Using E7 and E8 "TORX" socket wrenches, install the stud bolts.

Torque:
for stud bolt A, B, F 8.0 N*m (82 kgf*cm, 71 in.*lbf)
for stud bolt C 20 N*m (204 kgf*cm, 15 ft.*lbf)
for stud bolt D 12 N*m (122 kgf*cm, 9 ft.*lbf)
for stud bolt E 14 N*m (143 kgf*cm, 10 ft.*lbf)

2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

3. INSTALL PISTON SUB-ASSEMBLY WITH PIN
(a) Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

(b) Gradually heat the piston to about 60°C (140°F).
(c) Coat the piston pin with engine oil.

(d) Align the marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the snap ring.

NOTICE: For LH side, perform the assembly so that the marks of the piston and connecting rod are on the same side. For RH side, perform the assembly so that the marks of the piston and connecting rod are on opposite sides.

HINT: The piston and pin are a matched set.

(e) Check the fitting condition between the piston and piston pin.
(1) Move the connecting rod back and forth on the piston pin. Check the fitting condition.
If abnormal movement is felt, replace the piston and pin as a set.
(2) Rotate the piston back and forth on the piston pin. Check the fitting condition.
If abnormal movement is felt, replace the piston and pin as a set.

(f) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
(g) Install the oil ring expander and 2 side rails by hand.

(h) Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

Code mark:

4. INSTALL CRANKSHAFT BEARING

HINT:
^ Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
^ Upper bearings have an oil groove and oil holes; lower bearings do not.

(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

(b) Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

HINT: A number is marked on each bearing cap to indicate the installation position.

5. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Apply engine oil to the thrust washer set.
(b) Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

6. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and lower bearing, then place the crankshaft on the cylinder block.
(b) Install the 5 crankshaft bearing caps in their proper locations.

HINT: Place the bearing caps on the level and let them return to their original positions by their own weight.

NOTICE: Do not install the bearing caps by tapping them.

(c) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(d) Install the 10 crankshaft bearing cap bolts.

HINT: If any one of the bearing cap bolts is broken or deformed, replace it.

(1) Uniformly tighten the 10 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.

Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.

(2) Mark the front of the crankshaft bearing cap bolts with paint.
(3) Tighten the crankshaft bearing cap bolts another 90° as shown in the illustration.
(4) Check that the painted marks are now at a 90° angle to the front.
(e) Check that the crankshaft turns smoothly.

7. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod cap.

8. INSTALL PISTON AND CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
(b) Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE: Do not align the 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) Place the connecting rod cap on the connecting rod.
(1) Match the numbered connecting rod cap with the connecting rod.
(2) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.

(3) Check that the outside mark of the connecting rod cap is facing in the correct direction.

(e) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(f) Install the connecting rod cap bolts.

HINT: If any one of the connecting rod cap bolts is broken or deformed, replace it.

(1) Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
If any of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.

(2) Mark the front of the connecting cap bolt with paint.
(3) Tighten the cap bolts another 90° as shown in the illustration.
(4) Check that the painted marks are now at a 90° angle to the front.
(g) Check that the crankshaft turns smoothly.