Disassembly
COMPONENTS FOR CYLINDER BLOCK DISASSEMBLY
PREPARATION FOR DISASSEMBLY
1. REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.
2. REMOVE REAR END PLATE
Remove the bolt and end plate.
3. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
4. REMOVE ALTERNATOR
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEAD
7. REMOVE OIL PAN AND OIL PUMP
8. REMOVE OIL DIPSTICK GUIDE
Remove the bolt, and pull out the dipstick guide.
9. REMOVE WATER PUMP
CYLINDER BLOCK DISASSEMBLY
1. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts, retainer and gasket.
2. CHECK CONNECTING ROD THRUST CLEARANCE
sing a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 - 0.312 mm (0.0063 - 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. 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 nuts.
(c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.
HINT: Keep the lower bearing inserted with the connecting cap.
(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap. (See step 6 in cylinder block assembly in Engine mechanical)
Torque: 67 N.m (680 kgf.cm, 49 ft. lbf)
NOTICE: Do not turn the crankshaft.
(i) Remove the connecting rod cap. (See procedure (b) and (c) above)
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD 0.024 - 0.055 mm (0.0009 - 0.0022 in.)
U/S 0.25 0.023 - 0.069 mm (0.0009 - 0.0027 in.)
Maximum oil clearance: 08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crank- shaft.
HINT: If using a standard bearing. replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked "1", "2"and "3"accordingly.
Standard sized bearing center wall thickness:
Mark "1" 1.484 - 1.488 mm (0.0584 - 0.0586 in.)
Mark "2" 1.488 - 1.492 mm (0.0586 - 0.0587 in.)
Mark "3" 1.492 - 1.496 mm (0.0587 - 0.0589 in.)
(k) 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) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
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: 0.020 - 0.220 mm (0.0008 - 0.0087 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: 2.440 - 2.490 mm (0.0961 - 0.0980 in.)
6. 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 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearing and 2 lower thrust washers (No.3 main bearing cap only). Or, use the removed main bearing cap bolt and pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.3 main bearing cap only).
HINT:
- Keep the lower bearing and main bearing cap together.
- Arrange the main bearing caps and lower thrust washers in the correct order.
(c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper 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, grind or 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.
Torque: 59 N.m (600 kgf.cm, 43 ft. lbf)
NOTICE: Do not turn the crankshaft.
(i) Remove the main bearing caps. (See procedure (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance: No.3
STD 0.025 - 0.044 mm (0.0010 - 0.0017 in.)
U/S 0.25 0.021 - 0.061 mm (0.0008 - 0.0024 in.)
Others
STD 0.015 - 0.034 mm (0.0006 - 0.0013 in.)
U/S 0.25 0.029 - 0.069 mm (0.0011 - 0.0027 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be:
No.3 0.027 - 0.054 mm (0.0011 - 0.0021 in.)
Others 0.017 - 0.044 mm (0.0007 - 0.0017 in.)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or 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 selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.
Reference:
(k) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper bearings and 2 upper thrust washers from the cylinder block.
NOTE: Arrange the main bearing caps, bearings and thrust washers in correct order.