Part 1

Part 1:

Part 2:

CYLINDER BLOCK ASSY
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.





6. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Specified thrust clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
Connecting rod thickness: 20.80 to 20.85 mm (0.8189 to 0.8209 inch)
7. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.
c. Clean the crank pin, the bearing and the connecting rod.
d. Check the crank pin and bearing for pitting and scratches.





e. Lay a strip of plastigage across the crank pin.





f. Check that the protrusion of the connecting rod cap is facing the correct direction.
g. Apply a light coat of engine oil on the threads of the connecting rod cap bolts.





h. Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





i. Mark the front side of each connecting cap bolt with paint.
j. Retighten the cap bolts by 90° as shown in the illustration.

NOTICE: Do not turn the crankshaft.

k. Remove the 2 bolts, the connecting rod cap and the lower bearing.





l. Measure the plastigage at its widest point.
Specified oil clearance: 0.038 to 0.080 mm (0.0015 to 0.0031 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.
m. Completely remove the plastigage.





HINT: If replacing the bearing, replace it with one that has the same number as the connecting rod. There are 4 sizes of standard bearings: 1, 2, 3 and 4.





Standard bearing center wall thickness





8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push out the piston and the connecting rod assembly from the top of the cylinder block.

HINT:
^ Keep the bearings, the connecting rod and the cap together.
^ Arrange the piston and the connecting rod assemblies in correct order so they can be returned to the original locations when reassembling.

9. REMOVE CONNECTING ROD BEARING





10. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and oil ring by hand.





11. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.





12. REMOVE W/PIN PISTON SUB-ASSY
a. Gradually heat the piston to approximately 80°C (176°F).





b. 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.
^ Store the pistons, the pins, the rings, the connecting rods and the bearings in correct order so that they can be returned to the original locations when re assembling.





13. INSPECT CRANKSHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Specified thrust clearance: 0.04 to 0.30 mm (0.0016 to 0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft for wear, repair or replace if necessary.
Thrust washer thickness: 1.93 to 1.98 mm (0.0760 to 0.0780 inch).





14. CHECK OIL CLEARANCE
a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration.





b. Uniformly loosen and remove the 16 main bearing cap bolts the sequence shown in the illustration.





c. Remove the 4 main bearing caps and 4 lower bearings. Also remove the 2 lower thrust washers, located under the No. 2 main bearing cap.





NOTICE: Using a screwdriver, push up on the cap little by little, alternating from the right and left side until the cap is free. Take care not to damage the contact surfaces of the cap and 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.

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 42).

NOTICE: Do not turn the crankshaft.

j. Remove the main bearing caps (see steps (a) to (c)).





k. Measure the Plastigage at its widest point.





Specified oil clearance

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





HINT: If using a 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 on the next page for the appropriate bearing number. The No. 1 and No. 4 journal bearings have 5 standard bearing sizes, marked 3, 4, 5, 6 and 7 accordingly. The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked 1, 2, 3, 4 and 5 accordingly.





No. 1 and No. 4 journal bearings

HINT:
EXAMPLE:
Cylinder block imprinted number mark is 06
Crankshaft imprinted number mark is 08 6 + 8 = 14
Select the bearing marked "5"





No. 1 and No. 4 journal standard bearings selection chart





No. 2 and No. 3 journal bearings

HINT:
EXAMPLE
Cylinder block imprinted number mark is 06
Crankshaft imprinted number mark is 08 6 + 8 = 14
Select the bearing marked "3"





No.2 and No.3 journal standard bearings selection chart





Reference

15. REMOVE CRANKSHAFT
a. Lift 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.

16. REMOVE CRANKSHAFT THRUST WASHER SET
17. REMOVE CRANKSHAFT BEARING
18. CLEAN CYLINDER BLOCK

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.





19. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Using a precision straight edge and feeler gauge, mea sure the surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.





20. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.





Specified diameter

If the average of the measured diameters is greater than the maximum, replace the cylinder block.
21. INSPECT W/PIN PISTON SUB-ASSY
a. 1MZ-FE: Using a micrometer, measure the diameter at right angles to the piston pin center line and the distance from the pis ton head.





Distance





Piston diameter





HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with "R", the LH piston with "L".





b. 3MZ-FE: Using a micrometer, measure a diameter at right angles to the piston pin center line and the distance from the pis ton bottom.
Distance: 13.0 mm (0.512 inch)
Piston diameter: 91.953 to 91.967 mm (3.6202 to 3.6207 inch)
22. INSPECT PISTON OIL CLEARANCE





a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Specified oil clearance: 0.033 to 0.130 mm (0.0013 to 0.0051 inch)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.





23. INSPECT CONNECTING ROD SUB-ASSY
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1. Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If misalignment is greater than the 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 the twist is greater than the maximum, replace the connecting rod assembly.





24. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)





b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
c. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Specified oil clearance: 0.005 to 0.050 mm (0.0002 to 0.0020 inch)
If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and the piston pin together.