Part 3

ENGINE UNIT

COMPONENTS:

DISASSEMBLY (STEPS 41-68)

41. REMOVE WATER INLET HOUSING
a. Remove the 8 bolts and 2 nuts, then remove the water inlet housing.

42. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-07501
b. Using a socket hexagon wrench 12, remove the oil filter union.
43. REMOVE OIL PAN DRAIN PLUG
44. REMOVE OIL PAN SUB-ASSEMBLY NO. 2

a. Remove the 10 bolts and 2 nuts.

b. Insert the blade of SST between oil pan No. 1 and oil pan No. 2, cut off the sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Be careful not to damage the contact surfaces of oil pan No. 1 where the oil pan No. 2 is mounted.
^ Do not damage the flange portion of oil pan No. 2 when removing.

45. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt and 2 nuts, then remove the oil strainer and the gasket.
46. REMOVE OIL PAN SUB-ASSEMBLY

a. Loosen and remove the 15 bolts and 2 nuts uniformly.

b. Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.

NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.

47. REMOVE OIL PAN BAFFLE PLATE

48. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 6 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap.

49. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and a hammer, tap out the oil seal.

50. REMOVE OIL PUMP ASSEMBLY
a. Remove the 9 bolts.
b. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
c. Remove the O-ring.

51. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET

a. Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.

NOTICE: Be careful not to damage the baffle plate of the cylinder head cover.

b. Using a screwdriver and a hammer, tap out the gasket.

c. Using needle-nose pliers, pry out the gasket.

NOTICE: Be careful not to damage the cylinder head cover.

53. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
54. REMOVE WATER SEAL PLATE
55. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 1 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
56. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 2 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
57. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO. 3 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.

58. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 to 0.30 mm (0.0059 to 0.0118 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
59. 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 to the threads of the connecting rod cap bolts.

h. Tighten the bolts in several steps to 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.
Standard oil clearance: 0.038 to 0.066 mm (0.0015 to 0.0026 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)

NOTICE: Completely remove the Plastigage.

Standard Bearing Center Wall Thickness:

m. If replacing the 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.

60. REMOVE PISTON SUB-ASSEMBLY WITH 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.

61. REMOVE CONNECTING ROD BEARING

62. 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.

63. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.
64. REMOVE W/PIN PISTON SUB-ASSEMBLY

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.

65. INSPECT CRANKSHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 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. Check the crankshaft for wear, repair or replace if necessary.

HINT: Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 inch).

66. REMOVE CRANKSHAFT

a. Using several steps, loosen and remove the 8 main bearing cap bolts and seal washers uniformly in the sequence shown in the illustration.

b. Using several steps, loosen and remove the 16 main bearing cap bolts uniformly in the sequence shown in the illustration.

c. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and the lower bearings.

NOTICE:
^ Carefully pry out the main bearing cap by alternating lifting a little at a time on each end the cap.
^ Be careful not to damage the joint surface of the cylinder block and the main bearing cap.

d. Check the damaged the joint surface of the cylinder block and the bearing cap.
67. REMOVE CRANKSHAFT THRUST WASHER SET
68. REMOVE CRANKSHAFT BEARING