Disassembly

COMPONENTS FOR PREPARATION AND AFTER ASSEMBLY
PREPARATION FOR DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
2. REMOVE TIMING BELT AND PULLEYS
(See timing belt removal) Timing Components
3. REMOVE CYLINDER HEAD
(See cylinder head removal)
4. REMOVE GENERATOR
(See generator removal in Charging System)
5. REMOVE GENERATOR ADJUSTING BAR AND BRACKET
Remove the 3 nuts. generator adjusting bar and bracket.
6. REMOVE OIL PRESSURE SWITCH
(See oil pressure check in Lubrication System)
7. REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 3 bolts and compressor housing bracket.






8. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the 2 bolts and idler pulley bracket.






9. REMOVE KNOCK SENSORS
(a) Disconnect the 2 knock sensor connectors.
(b) Using SST, remove the 2 knock sensors. SST 09816-30010






10. REMOVE WATER INLET HOUSING
(a) Remove the engine wire band.
(b) Disconnect the engine wire clamp from the bracket.
(c) Remove the 8 bolts. 2 nuts and water inlet housing.
11. REMOVE WATER PUMP (See water pump removal in Cooling System) Water Pump
12. REMOVE NO.2 OIL PAN (See oil pump removal in Lubrication System)
13. REMOVE OIL STRAINER
(See oil pump removal in Lubrication System)
14. REMOVE NO.1 OIL PAN (See oil pump removal in Lubrication System)
15. REMOVE OIL PUMP
(See oil pump removal in Lubrication System) Oil Pump
16. REMOVE OIL FILTER
(See oil and filter replacement in Lubrication System)






17. REMOVE OIL FILTER UNION
Using a 12mm hexagon wrench, remove the oil filter union.
18. REMOVE WATER SEAL PLATE
Remove the 2 nuts and seal plate.
19. REMOVE ENGINE COOLANT DRAIN UNION






20. REMOVE EGR COOLER
Remove the 3 bolts, 2 nuts. EGR cooler and gasket.






COMPONENTS FOR CYLINDER BLOCK DISASSEMBLY AND ASSEMBLY






CYLINDER BLOCK DISASSEMBLY
1. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.






2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 - 0.30 mm (0.0059 - 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary. replace the crankshaft.
Connecting rod thickness: 20.80-20.85mm (0.8189 - 0.8209 in.)






3. 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 across the crank pin.






(g) Install the connecting rod cap with the 2 bolts. (See step 7 in cylinder block assembly)
Torque:
1st 24.5 N.m (250 kgf.cm, 18 ft.lbf)
2nd Turn 90°

NOTICE: Do not turn the crankshaft.






(h) Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above)
(I) Measure the Plastigage at its widest point.
Standard oil clearance: 0.038 - 0.064 mm (0.0015 - 0.0025 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.






HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.






Reference: Standard bearing center wall thickness
(j) Completely remove the Plastigage.






4. 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.
5. 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: 0.04 - 0.24 mm (0.0016 - 0.0095 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 1.930 - 1.980 mm (0.0760 - 0.0780 in.)






6. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE
(a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers, in the several passes. in the sequence shown.






(b) Uniformly loosen and remove the 16 main bearing cap bolts, in several passes, in the sequence shown.







(c) Using a screwdriver, pry out main bearing caps.
Remove the 4 main bearing caps, lower bearings and
(No.2 main bearing cap only) 2 lower thrust washers.

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

(d) Lift out the crankshaft.

HINT: Keep the upper bearings together with the cylinder block.

(e) Clean each main journal and bearing.
(f) 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.
(g) Place the crankshaft on the cylinder block.






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






(I) Install the 4 main bearing caps. (See step 4 in cylinder block assembly)

Torque:
12 pointed head bolt:
1st 22 N.m (225 kgf.cm, 16 ft.lbf)
2nd Turn 90°
Hexagon head bolt: 27 N.m (275 kgf.cm, 20 ft.lbf)

NOTICE: Do not turn the crankshaft.

(j) Remove the main bearing caps.
(See procedures (a) to (c) above)






(k) Measure the Plastigage at its widest point.
Standard oil clearance: 0.026 - 0.046 mm (0.0010 - 0.0018 in.)
Maximum clearance: 0.06 mm (0.0024 in.)






If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If using 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, then refer to the table below for the appropriate bearing number. There are 5 standard bearing sizes. marked "1", "2", "3", "4"and "5" accordingly.






EXAMPLE: Cylinder block "06"(A) + Crankshaft "08" (B) = Total number 14 (Use bearing "3")






Reference
(I) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block.

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