Disassembly

CYLINDER BLOCK:

CYLINDER BLOCK:

CYLINDER BLOCK
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
2. REMOVE TIMING CHAIN
3. REMOVE CYLINDER HEAD
4. REMOVE KNOCK SENSOR
5. REMOVE ENGINE WIRE CLAMPS
6. REMOVE PLUG




7. REMOVE OCV FILTER
Using a 12 mm hexagon wrench, remove the plug, gasket and OCV filter.

8. REMOVE WATER PUMP
9. REMOVE THERMOSTAT
10. REMOVE ENGINE COOLANT DRAIN UNION




11. REMOVE OIL DIPSTICK AND GUIDE
a. Remove the bolt, oil dipstick and guide.
b. Remove the O-ring from the oil dipstick.




12. REMOVE WATER BYPASS PIPE
Remove the 2 nuts, bolt, water bypass pipe and gasket.
13. REMOVE OIL PUMP
14. REMOVE OIL FILTER




15. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.




16. CHECK BALANCE SHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.050 to 0.090 mm (0.00197 to 0.00354 inch)
Maximum thrust clearance: 0.090 mm (0.00354 inch)
If the thrust clearance is greater than maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.
17. REMOVE BALANCE SHAFT HOUSING AND CHECK OIL CLEARANCE




a. Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown.
If the balance shaft housing is difficult to lift up, pry between the balance shaft housing and crank case with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the balance shaft housing and crank case.

HINT: Keep the lower bearing and balance shaft housing together.

b. Lift out the No. 1 and No. 2 balance shafts.

HINT: Keep the upper bearing with the crank case.

c. Clean each bearings and journals.
d. Check each bearings and journals for pitting and scratches.
If the bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
e. Place the No. 1 and No. 2 balance shafts on the crank case.




f. Lay a strip of Plastigage across each journal.
g. Install the balance shaft housing.

NOTICE: Do not turn the balance shaft.

h. Remove the balance shaft housing (See procedure (a) above).




i. Measure the Plastigage at its widest point.
Standard clearance: 0.004 to 0.049 mm (0.00016 to 0.00192 inch)
If the oil clearance is greater than standard, replace the bearings.
If necessary, replace the balance shaft.





HINT: If using a standard bearing, replace it with one having the same number.

Standard Bearing Center Wall Thickness:

Balance shaft journal diameter: 22.985 to 23.000 mm (0.90492 to 0.90551 inch)

Standard bearing center wall thickness:

18. REMOVE BALANCE SHAFT
a. Lift out the balance shaft.
b. Remove the 4 upper bearings from the crank case.

HINT: Arrange the bearings in the correct order.

19. REMOVE CRANK CASE




a. Uniformly loosen and remove the 11 bolts in several passes, in the sequence shown.




b. Using a screwdriver, remove the crank case by prying the portions between the crank case and cylinder block.

NOTICE: Be careful not to damage the contact surfaces of the crank case and cylinder block.

c. Remove the O-ring.

20. REMOVE CRANKSHAFT REAR OIL SEAL




21. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
Connecting rod thickness: 19.788 to 19.840 mm (0.7791 to 0.7811 inch)

22. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE




a. Check the matchmarks on the connecting rod and cap are aligned 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 on the crank pin.




g. Install the connecting rod cap.

NOTICE: Do not turn the crankshaft.

h. Remove the connecting rod cap (See procedure (b) and (c) above)




i. Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.





HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

Standard bearing center wall thickness (reference):

j. Completely remove the Plastigage.




23. 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 the correct order.




24. 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: 0.040 to 0.240 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
Thrust washer thickness: 1.930 to 1.980 mm (0.0760 to 0.0780 inch)
25. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE




a. Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown.




b. Using the 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings.

NOTICE: Be careful not to damage the cylinder block.

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

c. Lift out the crankshaft.

HINT: Keep the main bearings and 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, 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 cap (See procedure (a) and (b) above).




j. Measure the Plastigage at its widest point.
Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.







k 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 selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and 4 accordingly.

Cylinder Journal Diameter, Bearing Center Thickness. (reference):

l. Completely remove the Plastigage.

26. REMOVE CRANKSHAFT
a. Lift out the crankshaft.
b. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.

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




27. 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.




28. 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 the correct order only.

29. DISCONNECT CONNECTING ROD FROM PISTON




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




b. Gradually heat the piston to 80 to 90°C (176 to 194°F).




c. Using a plastic-faced hammer and a 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.