Disassembly
Part 1 Of 2:
Part 2 Of 2:
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
2. REMOVE CYLINDER HEAD
3. REMOVE WATER BYPASS PIPE
Remove the 2 nuts, bolts, water bypass pipe and gasket.
4. REMOVE THERMOSTAT
5. REMOVE KNOCK SENSOR
6. REMOVE ENGINE COOLANT DRAIN UNION
7. REMOVE OIL PUMP
8. REMOVE OIL FILTER
9. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.
10. REMOVE OIL PAN
a. Remove the 14 bolts and 2 nuts.
b. Insert the blade of SST between the bearing cap subassembly and oil pan, and cut off applied sealer and remove the oil pan.
SST 09032-00100
NOTICE:
^ Be careful not to the damage the oil pan contact surface of the bearing cap subassembly.
^ Be careful not to damage the oil pan flange.
11. REMOVE OIL STRAINER
Remove the 2 nuts, bolt, oil strainer and gasket.
12. 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 - 0.342 mm (0.0063 - 0.0135 inch)
Maximum thrust clearance: 0.342 mm (0.0135 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
Connecting rod thickness: 19.788 - 19.840 mm (0.7791 - 0.7811 inch)
13. 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 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: 0.028 - 0.060 mm (0.0011 - 0.0024 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the oil clearance is greater than 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.
Reference
Standard bearing center wall thickness:
j. Completely remove the Plastigage.
14. 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.
15. REMOVE BEARING CAP SUBASSEMBLY AND CRANKSHAFT REAR OIL SEAL, AND CHECK OIL CLEARANCE
a. Remove the 10 hexagon head bearing cap bolts.
b. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the sequence shown.
c. Using a screwdriver, remove the bearing cap subassembly by prying the portions between the cylinder block and bearing cap subassembly. Remove the 5 lower main bearings.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly.
HINT: Keep the lower bearing and bearing cap subassembly together.
d. Remove the crankshaft rear oil seal.
e. Lift out the crankshaft.
HINT: Keep the upper bearings together with the cylinder block.
f. Clean each main journal and bearing.
g. Check each main journal, bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
h. Place the crankshaft on the cylinder block.
i. Lay a strip of Plastigage across each journal.
j. Install the bearing cap subassembly.
NOTICE: Do not turn the crankshaft.
k. Remove the bearing cap subassembly (See procedures a. to d. above).
l. Measure the Plastigage at its widest point.
Standard oil clearance: 0.015 - 0.032 mm (0.0006 - 0.0013 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
m. 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.
EXAMPLE:
Cylinder block "4" (A) + Crankshaft "3" (B)
= Total number 7 (Use bearing "3")
Standard bearings selection chart
EXAMPLE: Cylinder block "4", Crankshaft "3", Use bearing "3"
Reference
n. Completely remove the Plastigage.
16. 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 - 0.0094 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: 2.430 - 2.480 mm (0.0957 - 0.0976 inch)
17. 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.
18. 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.
19. 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.
20. DISCONNECT CONNECTING ROD FROM PISTON
a. Using a small screwdriver, pry out the 2 snap rings.
b. Gradually heat the piston to 80 - 90°C (176 - 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.