Steps 36-70

ENGINE UNIT

COMPONENTS:

DISASSEMBLY (STEPS 36-70)
36. REMOVE CYLINDER HEAD COVER REAR

37. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug, gasket and valve filter.

38. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using a socket hexagon wrench 8, remove the hexagon bolt.

b. Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

39. REMOVE CYLINDER HEAD GASKET

40. REMOVE CYLINDER HEAD LH
a. Using a socket hexagon wrench 8, remove the hexagon bolt.

42. REMOVE WATER INLET HOUSING
a. Uniformly loosen and remove the 8 bolts and 2 nuts in the sequence shown in the illustration. Remove the water inlet housing.

43. 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.
44. REMOVE OIL PAN DRAIN PLUG

45. REMOVE OIL PAN SUB-ASSEMBLY NO. 2
a. Remove the 10 bolts and 2 nuts.

b. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2. Cut through the sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
^ Do not damage the flange portion of the oil pan No. 2 during removal.

46. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt and 2 nuts. Then remove the oil strainer and the gasket.

47. REMOVE OIL PAN SUB-ASSEMBLY
a. Uniformly loosen and remove the 15 bolts and 2 nuts, as shown in the illustration.

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.

48. REMOVE OIL PAN BAFFLE PLATE

49. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Uniformly loosen and 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.

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

51. 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.

52. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.

53. 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.

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

59. 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: 0.150 to 0.300 mm (0.0059 to 0.0118 inch)
Maximum thrust clearance: 0.350 mm (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)
60. 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. Lay a strip of Plastigage across the crank pin.
g. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

h. Tighten the bolts in several steps by the specified torque.
Torque: 25 Nm (255 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: 0.080 mm (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.

n. If replacing the bearing, replace it with one that has the same number as the connecting rod.

Standard Bearing Center Wall Thickness:

HINT: There are 4 sizes of standard bearings: 1, 2, 3 and 4.

61. 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 the correct order so they can be returned to their original locations when reassembled.

62. REMOVE CONNECTING ROD BEARING

63. 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.

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

65. 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 the correct order so that they can be returned to their original locations when reassembled.

66. 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 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)

67. INSPECT CRANKSHAFT OIL CLEARANCE
a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration (procedure "A").

b. Uniformly loosen and remove the 16 main bearing cap bolts in 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 (procedure "B").

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 the correct order.

d. Check the damaged the joint surface of the cylinder block and main bearing cap.

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 and 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 4 main bearing caps.

NOTICE: Do not turn the crankshaft.

k. Remove the main bearing caps (procedure "A" to "B").

l. Measure the Plastigage at its widest point.

Standard Oil Clearance:

Maximum Oil Clearance:

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

m. 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 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 & 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 & No. 4 Journal Standard Bearings Selection Chart (Part 1):

No. 1 & No. 4 Journal Standard Bearings Selection Chart (Part 2):

EXAMPLE: Cylinder block "06", crankshaft "08" = Use bearing "5"

No. 2 & 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 & No. 3 Journal Standard Bearings Selection Chart:

EXAMPLE: Cylinder block "06", crankshaft "08" = Use bearing "3"

Reference:

n. Completely remove the Plastigage.
68. 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.

69. REMOVE CRANKSHAFT THRUST WASHER SET
70. REMOVE CRANKSHAFT BEARING