Engine Mechanical 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.

Fig 2: Removing Oil Dipstick & Guide

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1. Remove the bolt, oil dipstick and guide.
2. Remove the O-ring from the oil dipstick.

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: Loosening Crankcase Bolts

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2. Using a screwdriver, remove the crank case by prying the portions between the crank case and cylinder block.
   Fig 6: Removing Crank Case Using A Screwdriver

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   NOTE: Be careful not to damage the contact surfaces of the crank case and cylinder block.
3. Remove the O-ring.

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

Fig 7: Measuring Thrust Clearance Using A Dial Indicator

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Standard thrust clearance: 

0.160 - 0.362 mm (0.0063 - 0.0143 in.) 

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.

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: Identifying Aligned Matchmarks On Connecting Rod & Cap

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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: Inserting Plastigage Strip On Crank Pin
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7. Install the connecting rod cap (See REASSEMBLY )
   NOTE: Do not turn the crankshaft.
8. Remove the connecting rod cap (See procedure (b) and (c) above).
   Fig 11: Installing Connecting Rod Cap

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9. Measure the Plastigage at its widest point.
   Fig 12: Measuring Plastigage

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   Standard oil clearance: 

   0.024 - 0.048 mm (0.0009 - 0.0019 in.) 

   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.

   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.
   Fig 13: Identifying Bearing Number Marks

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   STANDARD BEARING CENTER WALL THICKNESS SPECIFICATIONS
   
   

   Mark 1	1.485 - 1.488 mm (0.0585 - 0.0586 in.)
   Mark 2	1.488 - 1.491 mm (0.0586 - 0.0587 in.)
   Mark 3	1.491 - 1.494 mm (0.0587 - 0.0588 in.)

10. Completely remove the Plastigage.

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
Fig 14: Removing Carbon From Top Of Cylinder Using A Ridge Reamer
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2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

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

Fig 15: Measuring Thrust Clearance Using A Dial Indicator

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Standard thrust clearance: 

0.040 - 0.240 mm (0.0016 - 0.0094 in.) 

Maximum thrust clearance: 0.30 mm (0.0118 in.) 

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

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 16: Loosening & Removing Main Bearing Cap Bolts In Sequence

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2. Using the 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings.
   NOTE: Be careful not to damage the cylinder block.
   NOTE:

   • Keep the lower bearing and main bearing cap together.
   Fig 17: Removing Main Bearing Caps & Lower Bearings
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   • 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 18: Inserting Plastigage Across Each Journal

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6. Install the main bearing caps (See REASSEMBLY ).
   Fig 19: 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.
   Fig 20: Measuring Plastigage

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   Standard oil clearance: 

   0.017 - 0.040 mm (0.0007 - 0.0016 in.) 

   Maximum oil clearance: 0.050 mm (0.0020 in.) 

   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 21: Identifying Cylinder Block, Crankshaft & Used Bearing Marks

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   Fig 22: Cylinder Block & Crankshaft Marks Specifications

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   EXAMPLE:

   Cylinder block "4"

   + Crankshaft "3"

   = Total number 7 (Use bearing "3")

   Reference 

   Fig 23: Reference Chart

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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.

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.

Fig 24: Identifying Piston & Piston Pin Movement

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1. Using a piston ring expander, remove the 2 compression rings.
Fig 25: Removing Compression Rings Using A Piston Ring Expander
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2. Remove the 2 side rails and oil ring by hand.

1. Using a small screwdriver, pry out the 2 snap rings.
   Fig 26: Removing Snap Rings Using A Small Screwdriver

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2. Gradually heat the piston to 80 - 90°C (176 - 194°F).
   Fig 27: Heating Piston

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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 28: Tapping Piston Pin & Removing Connecting Rod Using A Plastic-Faced Hammer & A Brass Bar
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