Cylinder Block Disassembly

Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.15 to 0.55 mm (0.00591 to 0.0217 in.)

Maximum thrust clearance:

0.70 mm (0.0276 in.)

Check that the front mark on the connecting rod and cap are aligned to ensure correct reassembly.

Remove the 2 connecting rod cap bolts.

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 to the connecting rod cap.

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.

Clean the crank pin and bearing.

Lay a strip of Plastigage on the crank pin.

Place the connecting rod cap on the connecting rod with the front mark facing forward.

Text in Illustration

*1	Front Mark
	Front

Install and alternately tighten the bolts of the connecting rod cap in several steps.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

NOTICE:

Do not turn the crankshaft.

Mark the front side of each connecting rod cap bolt with paint.

Tighten the cap bolts 90° as shown in the illustration.

Check that the painted marks are now at a 90° angle to the front.

NOTICE:

Do not turn the crankshaft.

Remove the 2 connecting rod cap bolts.

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 to the connecting rod cap.

Measure the Plastigage at its widest point.

Standard oil clearance:

0.025 to 0.050 mm (0.000984 to 0.00197 in.)

Maximum oil clearance:

0.070 mm (0.00276 in.)

HINT:

1. If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. The standard thickness of each bearing is indicated by a 1, 2, 3 or 4 mark on its surface.
   
2. Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin.
   

Example:

Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3")

Standard Sized Bearing Center Wall Thickness:

Mark	Thickness
2	1.489 to 1.492 mm (0.0586 to 0.0587 in.)
3	1.492 to 1.495 mm (0.0587 to 0.0589 in.)
4	1.495 to 1.498 mm (0.0589 to 0.0590 in.)
5	1.498 to 1.501 mm (0.0590 to 0.0591 in.)
6	1.501 to 1.504 mm (0.0591 to 0.0592 in.)
7	1.504 to 1.507 mm (0.0592 to 0.0593 in.)

Connecting Rod Big End Inside Diameter:

Mark	Thickness
1	59.000 to 59.006 mm (2.32283 to 2.32307 in.)
2	59.006 to 59.012 mm (2.32307 to 2.32330 in.)
3	59.012 to 59.018 mm (2.32330 to 2.32354 in.)
4	59.018 to 59.024 mm (2.32354 to 2.32377 in.)

Crankshaft Pin Diameter:

Mark	Thickness
1	55.994 to 56.000 mm (2.20448 to 2.20472 in.)
2	55.988 to 55.994 mm (2.20425 to 2.20448 in.)
3	55.982 to 55.988 mm (2.20401 to 2.20425 in.)

Completely remove the Plastigage.

Perform the inspection above for each cylinder.

Using a ridge reamer, remove all the carbon from the top of the cylinder.

Remove the 16 cap bolts, 8 connecting rod caps and 8 lower bearings.

Push the 8 pistons and 8 connecting rods through the top of the cylinder block.

HINT:

1. Keep the bearing, connecting rod and cap together.
   
2. Arrange the piston and connecting rods in the correct order.
   

Remove the connecting rod bearings from the connecting rods and connecting rod caps.

HINT:

Arrange the removed parts in the correct order.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance:

0.020 to 0.220 mm (0.000787 to 0.00866 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

Standard thrust washer thickness:

2.44 to 2.49 mm (0.0961 to 0.0980 in.)

Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps in the sequence shown in the illustration.

Uniformly loosen and remove the 20 bearing cap bolts in several steps in the sequence shown in the illustration.

Using a screwdriver, slightly pry up the 5 main bearing caps.

NOTICE:

1. Be careful not to damage the joint surface of the cylinder block and main bearing caps.
   
2. Pry up the left and right side of the cap little by little.
   

HINT:

Tape the screwdriver tip before use.

Using the 2 inside position crankshaft bearing cap bolts, loosen each crankshaft bearing cap by moving it forward and backward, and remove each crankshaft bearing cap.

Remove the crankshaft.

Remove the crankshaft bearings from the bearing caps and cylinder block.

HINT:

Arrange the removed parts in the correct order.

Remove the thrust washer set from the cylinder block and No. 3 bearing cap.

Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

Using a piston ring expander, remove the 2 compression rings.

Remove the 2 side rails and oil ring expander by hand.

Disconnect the connecting rod from the piston.

1. Using a small screwdriver, pry off the 2 snap rings from the piston.
   

2. Gradually heat the piston to approximately 80°C (176°F).
   





3. Using a brass bar and plastic-faced hammer, lightly tap out the piston pin. Then remove the connecting rod.
   

   HINT:

   1. The piston and pin are a matched set.
      
   2. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
      

Clean the piston.

1. Using a gasket scraper, remove the carbon from the piston top.
   

2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
   

3. Using solvent and a brush, thoroughly clean the piston.
   

   NOTICE:

   Do not use a wire brush.