Disassembly
Part 1 Of 2:
Part 2 Of 2:
DISASSEMBLY
1. M/T: REMOVE FLYWHEEL
2. A/T: REMOVE DRIVE PLATE
3. REMOVE REAR END PLATE
4. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEADS
7. REMOVE WATER BYPASS PIPE WITH KNOCK SENSOR WIRE
a. Disconnect the 2 knock sensor connectors.
b. Remove the 2 bolts, nut and water bypass pipe with the knock sensor wire.
8. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the 3 bolts and idler pulley bracket
9. REMOVE KNOCK SENSORS
10. REMOVE WATER PUMP
11. REMOVE GENERATOR ADJUSTING BAR
12. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816-30010
13. REMOVE OIL FILTER
14. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the union.
15. REMOVE RH AND LH ENGINE MOUNTING BRACKETS
16. REMOVE COOLANT DRAIN COCK
17. w/ Oil Cooler: REMOVE OIL COOLER
18. REMOVE OIL PUMP
19. REMOVE REAR OIL SEAL RETAINER
a. Remove the 6 bolts and retainer.
b. Using a screwdriver
c. Remove the oil seal retainer by plying the portions between the oil seal retainer and main bearing cap
20. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.150 - 0.330 mm (0.0059 - 0.0130 inch)
Maximum thrust clearance: 0.380 mm (0.0150 inch)
If the thrust clearance is greater than maximum, replace the connecting rod assembly.
21. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
a. Check the matchmarks on the connecting rod and cap are aligned to ensure correct order.
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 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 with the 2 nuts.
NOTICE: Do not turn the crankshaft.
i. Remove the 2 nuts and connecting rod cap (See step (b) and (c) above).
j. Measure the Plastigauge 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 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.
Reference
Standard bearing center wall thickness:
k. Completely remove the Plastigauge.
22. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
a. Using a ridge reamer, remove the all 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 correct order.
23. 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: 0.300 mm (0.0118 inch)
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 inch)
24. REMOVE MAIN BEARING CAP AND CHECK OIL CLEARANCE
a. Uniformly loosen and remove the main bearing cap bolts, in several passes, in the sequence shown.
b. Using a screwdriver, pry out the main bearing cap and remove the main bearing cap, lower main bearings and lower thrust washers (No.2 journal position of main bearing cap only).
HINT: Keep the lower main bearings and lower thrust washers together with the main bearing cap.
c. Lift out the crankshaft.
HINT: Keep the upper main bearings 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 cap with the 8 bolts.
NOTICE: Do not turn the crankshaft.
i. Remove the 8 bolts and main bearing cap (See step (a) and (b) above).
j. Measure the Plastigauge 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 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.
EXAMPLE: Cylinder block "2" + Crankshaft, "1" = Total number 3 (Use bearing "3")
Reference
Standard sized bearing center wail thickness
Cylinder block main journal bore diameter
Crankshaft main journal diameter
k. Completely remove the Plastigauge
25. REMOVE CRANKSHAFT
a. Lift out the crankshaft.
b. Remove the upper main bearings and upper thrust washers from the cylinder block.
HINT: Arrange the main bearings and thrust washers in correct order.
26. 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
27. 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.
28. DISCONNECT CONNECTING ROD FROM PISTON
a. Using a small screwdriver, pry out the 2 snap rings.
b. Gradually heat the piston to about 60°C (140°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.