Disassembly

DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
2. REMOVE TIMING CHAIN
3. REMOVE CYLINDER HEAD
4. REMOVE ENGINE WIRE
5. REMOVE THERMOSTAT
6. REMOVE WATER PUMP
7. REMOVE OIL LEVEL GAUGE AND GUIDE
8. REMOVE WATER BY-PASS PIPE NO. 1
Remove the 2 nuts, bolt, water by-pass pipe and gasket.
9. REMOVE DRAIN PLUG
10. REMOVE OIL PUMP
11. REMOVE KNOCK SENSOR
12. REMOVE ENGINE WIRE CLAMP





13. REMOVE OCV FILTER
Using a 12 mm hexagon wrench, remove the plug, gasket and OCV filter.





14. CHECK BALANCE SHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.050 - 0.090 mm (0.00197 - 0.00354 inch)
Maximum thrust clearance: 0.090 mm (0.00354 inch)
If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.
15. REMOVE BALANCE SHAFT HOUSING AND CHECK OIL CLEARANCE





a. Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown in the illustration.
If it is difficult to lift up the balance shaft housing, pry between the balance shaft housing and crank case with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the balance shaft housing and crank case.

HINT: Keep the lower bearing and balance shaft housing together.

b. Lift out the No. 1 and No. 2 balance shafts.

HINT: Keep the upper bearing with the crank case.

c. Clean each bearings and journals.
d. Check each bearings and journals for pitting and scratches.
If the bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
e. Place the No. 1 and 2 balance shafts on the crank case.





f. Lay a strip of the Plastigage across each journal.
g. Install the balance shaft housing.
Torque:
1st 22 Nm (224 kgf-cm, 16 ft. lbs.)
2nd Turn extra 90°

NOTICE: Do not turn the balance shaft.

h. Remove the balance shaft housing (See procedure a.).





i. Measure the Plastigage at its widest point.
Standard clearance: 0.004 - 0.031 mm (0.00016 - 0.00122 inch)
If the oil clearance is greater than the standard, replace the bearings. If necessary, replace the balance shaft.





HINT: If using a standard bearing, replace it with one having the same number.





Balance shaft housing journal bore diameter (Reference)

Balance shaft journal diameter: (Reference) 22.985 - 23.000 mm (0.90492 - 0.90551 inch)





Standard bearing center wall thickness (Reference)

16. REMOVE BALANCE SHAFT
a. Lift out the balance shaft.
b. Remove the 4 upper bearings from the crank case.

HINT: Arrange the bearings in the correct order.





17. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.





18. REMOVE CRANK CASE
a. Uniformly loosen and remove the 11 bolts, in several passes, in the sequence shown in the illustration.
b. Using a screwdriver, remove the crank case by prying the portions between the crank case and cylinder block.

NOTICE: Be careful not to damage the contact surfaces of the crank case and cylinder block.

c. Remove the O-ring.
19. REMOVE CRANKSHAFT REAR OIL SEAL





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: 0.160 - 0.362 mm (0.00630 - 0.01425 inch)
Maximum thrust clearance: 0.362 mm (0.01425 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crank shaft.
Connecting rod thickness: 19.788 - 19.840 mm (0.77905 - 0.78110 inch)
21. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
a. Check the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.





b. Remove the 2 connecting rod cap bolts.
c. 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 with the connecting rod cap.

d. Clean the crank pin and bearing.
e. 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.





f. Lay a strip of the Plastigage the crank pin.





g. Install the connecting rod cap with the 2 bolts.
Torque: 1st 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
2nd Turn extra 90°

NOTICE: Do not turn the crankshaft.

h. Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure b. and c.)





i. Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 - 0.048 mm (0.0009 - 0.0019 inch)
Maximum oil clearance: 0.08 mm (0.0031 inch)
If the oil clearance is greater than standard, replace the bearings. If necessary, replace the crankshaft..





HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.





Standard bearing center wall thickness (Reference)

j. Completely remove the Plastigage.





22. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. 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.





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: 0.04 - 0.24 mm (0.0016 - 0.0094 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 1.980 - 1.930 mm (0.07795 - 0.07598 inch)
24. 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 in the illustration.





b. Using the 2 removed main bearing cap bolts, remove the main bearing caps and 5 lower bearings.

NOTICE: Be careful not to damage the cylinder block.

HINT:
- Keep the lower bearing and main bearing cap together.
- Arrange the main bearing caps in correct order.

c. Lift out the crankshaft.

HINT: Keep the upper bearings 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.
It necessary, 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.
Torque:
1st 40 Nm (408 kgf-cm, 30 ft. lbs.)
2nd Turn extra 90°

NOTICE: Do not turn the crankshaft.

i. Remove the main bearing cap (See procedure a. to b.).





j. Measure the Plastigage at its widest point.
Standard oil clearance: 0.008 - 0.024 mm (0.00031 - 0.00094 inch)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.








k. 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 up the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3", and "4" accordingly.





Reference

l. Completely remove the Plastigage.
25. REMOVE CRANKSHAFT
a. Lift out the crankshaft.
b. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.

HINT: Arrange the main bearings and thrust washers in the correct order.





26. CHECK FIT BETWEEN PISTON AND PISTON PIN
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: Set out the piston rings in the way that their upside and down side can be recognized.

28. 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 uses a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.