Cylinder Block: Disassembly

Fig 1: Removing OCV Filter

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

1. Remove the bolt, oil dipstick and guide.
2. Remove the O-ring from the oil dipstick.
Fig 2: Removing Oil Dipstick & Guide
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Fig 3: Removing Water Bypass Pipe

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Remove the 2 nuts, bolt, water bypass pipe and gasket.

Fig 4: Removing Oil Filter Union

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Using a 12 mm hexagon wrench, remove the oil filter union.

1. Uniformly loosen and remove the 11 bolts in several passes, in the sequence shown.
   Fig 5: Locating Crank Case Bolts

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2. Using a screwdriver, remove the crank case by prying the portions between the crank case and cylinder block.
   NOTE: Be careful not to damage the contact surfaces of the crank case and cylinder block.
3. Remove the O-ring.

Fig 7: Checking Connecting Rod Thrust Clearance

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

1. Standard thrust clearance: 0.160 - 0.362 mm (0.0063 - 0.0143 in.) 
2. Maximum thrust clearance: 0.362 mm (0.0143 in.) 

If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

1. Connecting rod thickness: 19.788 - 19.840 mm (0.7791 - 0.7811 in.) 

1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
   Fig 8: Removing Connecting Rod Caps

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3. 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.
   Fig 9: Removing Connecting Rod Cap & Lower Bearing

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   NOTE: Keep the lower bearing inserted with the connecting rod cap.
4. Clean the crank pin and bearing.
5. 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.

6. Lay a strip of Plastigage on the crank pin.
   Fig 10: Locating Crank Pin

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7. Install the connecting rod cap (See REASSEMBLY ).
   Fig 11: Installing Connecting Rod Cap

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   NOTE: Do not turn the crankshaft.
8. Remove the connecting rod cap (See procedure  b and  c above).
9. Measure the Plastigage at its widest point.
   1. Standard oil clearance: 0.024 - 0.048 mm (0.0009 - 0.0019 in.) 
   2. Maximum oil clearance: 0.08 mm (0.0031 in.) 

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

   Fig 12: Measuring Plastigage

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   NOTE: 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.

   Reference 

   Standard bearing center wall thickness: 

   Fig 13: Identifying Number Marked On Connecting Rod

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   Fig 14: Displaying Standard Bearing Center Wall Thickness

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10. Completely remove the Plastigage.

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
Fig 15: Removing Piston & Connecting Rod Assemblies
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Fig 16: Checking Crankshaft Thrust Clearance

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

1. Standard thrust clearance: 0.040 - 0.240 mm (0.0016 - 0.0094 in.) 
2. Maximum thrust clearance: 0.30 mm (0.0118 in.) 

If the thrust clearance is greater than maximum, replace the thrust washers as a set.

1. Thrust washer thickness: 1.930 - 1.980 mm (0.0760 - 0.0780 in.) 

1. Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown.
   Fig 17: Locating & Removing Main Bearing Caps

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2. Using the 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings.
   Fig 18: Removing Bearing Caps & Lower Bearings

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   NOTE: Be careful not to damage the cylinder block.
   NOTE:

   • Keep the lower bearing and main bearing cap together.
   • Arrange the main bearing caps in the correct order.
3. Lift out the crankshaft.
   NOTE: Keep the main bearings and thrust washers together with the cylinder block.
4. Place the crankshaft on the cylinder block.
5. Lay a strip of Plastigage across each journal.
   Fig 19: Laying Plastigage On Each Journal

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6. Install the main bearing caps (See REASSEMBLY ).
   Fig 20: Installing Main Bearing Caps

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   NOTE: Do not turn the crankshaft.
7. Remove the main bearing cap (See procedure  a and  b above).
8. Measure the Plastigage at its widest point.
   1. Standard oil clearance: 0.017 - 0.040 mm (0.0007 - 0.0016 in.) 
   2. Maximum oil clearance: 0.050 mm (0.0020 in.) 
   Fig 21: Measuring Plastigage At Widest Point
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   If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

9. 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 together 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.
   Fig 22: Displaying Cylinder Block & Crankshaft

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   Fig 23: Displaying Standard Bearing Sizes

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   EXAMPLE:

   Cylinder block "4"

   + Crankshaft "3"

   = Total number 7 (Use bearing "3")

   Reference 

   Fig 24: Displaying Specifications

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10. Completely remove the Plastigage.

1. Lift out the crankshaft.
2. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.

Fig 25: Checking Fit Between Piston & Piston Pin

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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.

1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
Fig 26: Removing Piston Rings
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1. Using a small screwdriver, pry out the 2 snap rings.
   Fig 27: Disconnecting Connecting Rod From Piston

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2. Gradually heat the piston to 80 - 90°C (176 - 194°).
   Fig 28: Heating Pistons

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

Fig 29: Removing Connecting Rod From Piston

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