Disassembly

DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
2. REMOVE TIMING BELT AND PULLEYS
3. REMOVE CYLINDER HEAD ASSEMBLY
a. Remove the 3 bolts and No.3 timing belt cover.
b. Remove the cylinder head cover.
1. Disconnect the PCV hose from the intake manifold.
2. Remove the 4 nuts, 4 grommets, head cover and gasket.
c. Remove the camshafts.
d. Disconnect the knock sensor 1 connector.
e. Disconnect the crankshaft position sensor connector.
f. Disconnect the wire clamp from the generator drive belt adjusting bar.
g. Disconnect the IAC valve water bypass hose from the water bypass pipe.
h. Disconnect the water bypass hose (from the water bypass pipe) from the water outlet.
i. Remove the bolt holding the VSV for EGR to the intake manifold.
j. Remove the 2 bolts holding the water bypass pipe to the cylinder head.
k. Remove the cylinder head assembly.
4. REMOVE OIL DIPSTICK
5. REMOVE OIL PAN AND OIL PUMP
a. Disconnect the crankshaft position sensor connector from the generator drive belt adjusting bar.
b. Remove the oil pan and oil pump.
6. REMOVE PS PUMP BRACKET
Remove the 3 bolts and pump bracket.
7. REMOVE KNOCK SENSOR 1
8. REMOVE OIL FILTER

9. REMOVE WATER PUMP, WATER BYPASS PIPE AND OIL COOLER (w/ OIL COOLER) ASSEMBLY
a. w/ Oil Cooler: Remove the nut and union bolt, and disconnect the oil cooler. Remove the O-ring.





b. Remove the bolt and generator drive belt adjusting bar.
c. Remove the 3 bolts in the sequence shown, remove the water pump, water bypass pipe, oil cooler (w/ oil cooler) assembly and O-ring.





10. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts, retainer and gasket.





11. CHECK THRUST CLEARANCES OF NO.1 AND NO.2 BALANCE SHAFTS OF ENGINE BALANCER
Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.060 - 0.110 mm (0.0024 - 0.0043 inch)
Maximum clearance: 0.11 mm (0.0043 inch)
If the clearance is greater than maximum, replace the balance shaft housings and bearings. If necessary, replace the balance shafts.
12. CHECK AND ADJUST BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR





NOTICE: Backlash between the crankshaft gear and No.1 balance shaft gear varies with the rotation of the balance shaft and the deviation of the crankshaft gear. Accordingly, it is necessary to measure the backlash at the 4 points shown in the illustration.





a. Turn the crankshaft 2 or 3 times to settle the crankshaft gear and No.1 balance shaft gear.
b. When the No.1 piston is at TDC, check that the punch marks shown in the illustration of the balance shafts are aligned with the grooves of the No.2 housing.





c. Check that punch marks A and B are at the positions on the No.1 balance shaft indicated in the illustration.





d. First turn the crankshaft clockwise, and align the groove of the No.2 balance shaft housing with punch mark A of the No.1 balance shaft.





e. Set SST and a dial indicator as shown in the illustration.
SST 09224-74010

HINT: Make sure that the needle of the dial indicator is perpendicular to the SST and that it is placed in the middle of the 3rd indention.





f. Lightly turn the No.1 balance shaft by hand and measure the backlash.

HINT:
- Turn the No.1 balance shaft 4 or 5 times to provide a steady backlash reading.
- To prevent excessive backlash due to thrust clearance, measure the backlash while pressing on the rear of the No.1 balance shaft.

Standard backlash (at punch mark A): 0.005 - 0.040 mm (0.0002 - 0.0016 inch)

NOTICE: Do not turn the No.1 balance shaft strongly.





g. Remove the dial indicator and SST.
h. Turn the crankshaft clockwise to align the groove of the No.2 housing with punch mark B.
i. Set the dial indicator. (See step (e))
j. Measure the backlash. (See step (f))
Standard backlash (at punch mark B): 0.005 - 0.060 mm (0.0002 - 0.0024 inch)
k. Remove the dial indicator.





l. Turn the crankshaft clockwise again to align the groove of the No.2 housing with punch mark A.
m. Set the dial indicator. (See step (e))
n. Measure the backlash. (See step (f))
Standard backlash (at punch mark A): 0.005 - 0.040 mm (0.0002 - 0.0016 inch)
o. Remove the dial indicator.





p. Turn the crankshaft clockwise again to align the groove of the No.2 housing with punch mark B.
q. Set the dial indicator. (See step (e))
r. Measure the backlash. (See step (f))
Standard backlash (at punch mark B): 0.005 - 0.060 mm (0.0002 - 0.0024 inch)
s. Remove the dial indicator.
If even one of the 4 points measured above exceeds the backlash specification, adjust the backlash with new spacers.

NOTICE: Use the same size spacers for both the left and right sides.

HINT:
- Varying the spacer thickness by 0.02 mm (0.0008 inch) change the backlash by about 0.014 mm (0.0006 inch).
- If the backlash is greater than permitted maximum, select a thinner shim.
- If the backlash is less than the specification, select a thicker shim.





Adjusting Spacer Selection Chart (Off-Vehicle)





13. REMOVE ENGINE BALANCER
a. Uniformly loosen and remove the 6 bolts in several passes, in the sequence shown.
b. Remove the engine balancer and spacers.





14. 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 - 0.312 mm (0.0063 - 0.0123 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
15. 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. lbs.) the connecting rod cap.

HINT: Keep the lower bearing inserted with the connecting rod 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.

NOTICE: Do not turn the crankshaft.

i. Remove the connecting rod cap. (See steps (b) and (c))





j. Measure the Plastigage at its widest point.





Standard oil clearance

Maximum oil clearance: 0.08 mm (0.0031 inch)
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 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

k. Completely remove the Plastigage.
16. 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.

HINT:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.





17. 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 washer as a set.
Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 inch)
18. 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 bearings and 2 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.

NOTICE: Do not turn the crankshaft.

i. Remove the main bearing caps. (See steps (a) and (b))





j. Measure the Plastigage at its widest point.





Standard clearance

Maximum clearance: 0.08 mm (0.0031 inch)

HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be:





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.





Cylinder block main journal bore diameter





Crankshaft main journal diameter

Standard sized bearing center wall thickness:





No.3





Others





20. 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.





21. REMOVE PISTON RINGS
a. Using a piston ring expander, remove the No.1 and No.2 piston rings.
b. Remove the 2 side rails and oil ring expander by hand.

HINT: Arrange the piston rings in correct order only.

22. 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 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.