CYLINDER BLOCK > DISASSEMBLY

for Preparation Click here



1. INSPECT CONNECTING ROD THRUST CLEARANCE


    A084165
  1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

    Standard thrust clearance:
    0.16 to 0.36 mm (0.00630 to 0.0142 in.)

    Maximum thrust clearance:
    0.36 mm (0.0142 in.)
    If the thrust clearance is greater than the maximum, replace the connecting rod.


2. INSPECT CRANKSHAFT THRUST CLEARANCE


    A084170E01
  1. 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 (0.00157 to 0.00945 in.)

    Maximum thrust clearance:
    0.3 mm (0.0118 in.)
    If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
    Reference 
    Item
    Thrust Washer Thickness
    Thrust Clearance
    STD
    2.43 to 2.48 mm (0.0957 to 0.0976 in.)
    0.04 to 0.24 mm (0.00157 to 0.00945 in.)
    O/S 0.125
    2.493 to 2.543 (0.0981 to 0.100 in.)
    0.04 to 0.24 mm (0.00157 to 0.00945 in.)
    O/S 0.250
    2.555 to 2.605 (0.101 to 0.103 in.)
    0.04 to 0.24 mm (0.00157 to 0.00945 in.)


3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    A001166E01
  1. Using a ridge reamer, remove all carbon from the top of the cylinder.

  1. Mark each cylinder No. on the connecting rod and connecting rod cap with paint.



    A265787E01
  1. Using SST, remove the 2 connecting rod cap bolts.

    SST
    09205-16010  


    A270271
  1. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap with connecting rod bearing by wiggling the connecting rod cap right and left.

  1. Clean the crank pin and connecting rod bearing.

    NOTICE:
    Check the crank pin and connecting rod bearing for pitting and scratches.

    HINT:
    Keep the connecting rod bearing inserted in the connecting rod cap.
  1. Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block.

    HINT:
    1. Keep each connecting rod bearing, connecting rod and connecting rod cap as a set.
    2. Arrange the removed parts in the correct order.


4. REMOVE CONNECTING ROD BEARING
  1. Remove the 8 connecting rod bearings.

    HINT:
    Arrange the removed parts in the correct order.


5. REMOVE PISTON RING SET


    A084172E01
  1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.

  1. Remove the oil ring and oil ring expander by hand.

    HINT:
    Arrange the removed parts in the correct order.


6. REMOVE PISTON SUB-ASSEMBLY WITH PISTON PIN


    A084173E01
  1. Using SST, press out the piston pin from the piston.

    SST
    09221-25026   (09221-00021, 09221-00030, 09221-00061, 09221-00090, 09221-00100)

    HINT:
    1. The piston and pin are a matched set.
    2. Arrange the removed parts in the correct order.


7. REMOVE CRANKSHAFT


    A084171E06
  1. Using several steps, uniformly loosen and remove the 10 crankshaft bearing cap bolts with a 12 mm socket wrench for 12 pointed head in the sequence shown in the illustration.



    A270307
  1. Using the 2 removed crankshaft bearing cap bolts, remove the 5 crankshaft bearing caps.

    HINT:
    1. Keep each No. 2 crankshaft bearing and crankshaft bearing cap as a set.
    2. Arrange the removed parts in the correct order.


    A265794
  1. Remove the crankshaft from the cylinder block.



8. REMOVE UPPER CRANKSHAFT THRUST WASHER


    A265795
  1. Remove the 2 upper crankshaft thrust washers from the cylinder block.

    HINT:
    Arrange the removed parts in the correct order.


9. REMOVE CRANKSHAFT BEARING


    A265796
  1. Remove the 5 upper crankshaft bearings from the cylinder block.

    HINT:
    Arrange the removed parts in the correct order.


    A198046
  1. Remove the 5 lower crankshaft bearings from the crankshaft bearing cap.

    HINT:
    Arrange the removed parts in the correct order.


10. REMOVE WATER BY-PASS HOSE UNION


    A265797
  1. Using a 17 mm deep socket wrench, remove the water by-pass hose union from the cylinder block.



11. REMOVE OIL JET


    A265798
  1. Remove the oil jet from the cylinder block.