Disassembly

DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND
2. REMOVE TIMING BELT AND PULLEYS
3. REMOVE CYLINDER HEAD
4. REMOVE RH ENGINE MOUNTING BRACKET
5. REMOVE LH ENGINE MOUNTING BRACKET
6. REMOVE STARTER
7. REMOVE KNOCK SENSORS
8. REMOVE ENGINE WIRE





a. Disconnect the crankshaft position sensor connector.
b. Remove the 2 bolts and engine wire cover from the LH side of the cylinder block.





c. Remove the 2 bolts, and disconnect the engine wire from the RH side of the cylinder block.
d. Remove the bolt and engine wire.
9. REMOVE WATER PUMP
10. REMOVE NO.2 OIL PAN
11. REMOVE OIL PAN BAFFLE PLATE
12. REMOVE NO.1 OIL PAN
13. REMOVE OIL STRAINER
14. REMOVE OIL PUMP





15. REMOVE WATER SEAL PLATE
Remove the 2 bolts and seal plate.
16. REMOVE ENGINE COOLANT DRAIN UNIONS
Remove the RH and LH drain unions.





17. REMOVE REAR OIL SEAL RETAINER
a. Remove the 7 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.
c. Remove the O-ring.





18. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth.
Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 inch)
19. REMOVE CONNECTING ROD CAPS AND CHECK 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 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.

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: 0.027 - 0.053 mm (0.0011 - 0.0021 inch)
Maximum oil clearance: 0.065 mm (0.0026 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.





HINT: 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 connecting rod cap and crankshaft, then selecting 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" = Total number 4 (Use bearing "4")
Reference





Connecting rod big end inside diameter:





Crankshaft crank pin diameter:





Standard sized bearing center wall thickness:
a. Completely remove the Plastigage.





20. 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 correct order.





21. 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: 0.020 - 0.220 mm (0.0008 - 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 inch)
22. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE





a. Remove the 10 main bearing cap bolts.





b. Uniformly loosen and remove the 20 main bearing cap bolts in several passes, in the sequence shown.





c. Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 main bearing cap only).

NOTICE: Be careful not to damage the cylinder block.

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.
e. Remove the 2 upper thrust washers.

HINT:
- Arrange the upper thrust washers in correct order.
- Keep the upper bearings together with the cylinder block.

f. Clean each main journal and bearing.
g. 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.





h. Install the 10 main bearings and 5 main bearing caps with the 30 bolts. Do not install the crankshaft.





i. Using a cylinder gauge, measure the inside diameter of the main bearing.
Bearing inside diameter: 66.986 - 67.000 mm (2.6372 - 2.6378 inch)
j. Measure the diameter of the main journal.
k. Subtract the main journal diameter measurement from the main bearing inside diameter measurement.





Standard clearance:





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





HINT: 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 refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked "3", "4", "5", "6" and 7". For others position bearings, use bearings marked "1 ", "2", "3", "4" and "5".






No.1, No.5:
EXAMPLE:
Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "4" (Upper), "5" (Lower))





Others:
EXAMPLE:
Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "2" (Upper), "3" (Lower))

Reference

Cylinder block main journal bore diameter (A):





Crankshaft main journal diameter (B):





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





Others





l. Remove the 10 bolts, 20 nuts, 5 main bearing caps and 5 lower main bearing. (See procedure (a) to (c) above)
m. Remove the 5 upper main bearings from the cylinder block.

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





23. 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.





24. 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 correct order only.

25. DISCONNECT CONNECTING ROD FROM PISTON





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





b. Gradually heat the piston to approx. 60°C (140°F).





c. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and 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 correct order.

INSPECTION





1. CLEAN CYLINDER BLOCK
a. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
b. Using a soft brush and solvent, thoroughly clean the cylinder block.

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45° or less.

2. INSPECT CYLINDER BLOCK





a. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.





b. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.





c. Inspect the cylinder bore diameter.

HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.





Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.





Standard diameter:
Maximum diameter: 87.73 mm (3.4539 inch)
If the diameter is greater than maximum, replace the cylinder block.





d. Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.





e. Using vernier calipers, measure the tension portion diameter of the main bearing cap bolt.
Standard diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 inch)
Minimum diameter: 7.20 mm (0.2835 inch)
If the diameter is less than minimum, replace the cap bolt.
3. CLEAN PISTON





a. Using a gasket scraper, remove the carbon from the piston top.





b. Using a groove cleaning tool or broken ring, clean the piston ring grooves.





c. Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.

4. INSPECT PISTON AND CONNECTING ROD
a. Inspect the piston oil clearance.

HINT: There are 3 sizes of the standard piston diameter, marked "1" "2" and "3" accordingly. The mark is stamped on the piston top.





1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 26.5 mm (1.043 inch) from the piston head.





Piston diameter:
2) Measure the cylinder bore diameter in the thrust directions. (See step 2 above)
3) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.084 - 0.104 mm (0.0033 - 0.0041 inch)
Maximum oil clearance: 0.124 mm (0.0049 inch)
If the oil clearance is greater than maximum, replace all the 8 pistons. If necessary, replace the cylinder block.





HINT: Use new cylinder block:
- Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
- The shape of the piston varies for the LH and RH banks. The LH piston is marked with "L", the RH piston with "R".





b. Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.





Ring groove clearance:
If the clearance is not as specified, replace the piston.





c. Inspect the piston ring end gap.
1) Insert the piston ring into the cylinder bore.
2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 inch) from the top of the cylinder block.





3) Using a feeler gauge, measure the end gap.





Standard end gap:






Maximum end gap:
If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.





d. Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.





e. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1) Check for bend.
Maximum bend: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If bend is greater than maximum, replace the connecting rod assembly.





2) Check for twist
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If twist is greater than maximum, replace the connecting rod assembly.





f. Inspect the piston pin oil clearance.
1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 inch)





2) Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 inch)
3) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.





g. Using vernier calipers, measure the tension portion of the connecting rod bolt.
Standard diameter: 7.200 - 7.300 mm (0.2835 - 0.2874 inch)
Minimum diameter: 7.00 mm (0.2756 inch)
If the diameter is less than minimum, replace the bolt.
5. INSPECT CRANKSHAFT
a. Inspect for circle runout.





1) Place the crankshaft on V-blocks.
2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.08 mm (0.0031 inch)
If the circle runout is greater than maximum, replace the crankshaft.





b. Inspect the main journals and crank pins.
1) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter: 66.988 - 67.000 mm (2.6373 - 2.6378 inch)
Crank pin diameter: 51.982 - 52.000 mm (2.0465 - 2.0472 inch)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
2) Check each main journal and crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than maximum, replace the crankshaft.