Engine Unit: Disassembly

1. Remove the bolt, 2 nuts, pipe and gasket.
   Fig 1: Identifying No. 1 Water By-Pass Pipe

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1. Remove the bolt, 2 nuts, pipe and gasket.
   Fig 2: Identifying No. 3 Water By-Pass Pipe

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1. Using a 12 mm hexagon wrench, remove the oil filter union.
   Fig 7: Identifying Oil Filter Union

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1. Remove the oil pan drain plug and gasket.

1. Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
2. Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
Fig 12: Identifying Bearing Cap Bolts In Sequence
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1. Using needle-nose pliers, remove the cylinder block water jacket spacer from the water jacket.
   NOTE: Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.
   Fig 14: Identifying Cylinder Block Water Jacket Spacer

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1. Using a 6 mm socket hexagon wrench, remove the plug and gasket.
2. Remove the oil control valve filter.
   Fig 16: Identifying Oil Control Valve Filter

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1. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.

   Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 in.) 

   Maximum thrust clearance: 0.09 mm (0.0035 in.) 

   If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.

   Fig 17: Inspecting Balance Shaft Thrust Clearance

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1. Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.
2. Remove the balance shaft housing from the crankcase.

   HINT:

   Keep the lower bearing and balance shaft housing together.

   Fig 18: Identifying Balance Shaft Oil Clearance Bolts In Sequence

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

   HINT:

   Keep the upper bearing with the crankcase.

   Fig 19: Identifying Balance Shafts

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4. Clean each bearing and journal.
5. Check each bearing and journal for pitting and scratches.

   If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.

6. Inspect the balance shaft housing bolt.
   1. Using a vernier caliper, measure the length of the bolts from the seat to the end.

      Standard bolt length: 58.3 to 59.7 mm (2.295 to 2.350 in.) 

      Maximum bolt length: 60.3 mm (2.374 in.) 

      If the bolt length is greater than the maximum, replace the balance shaft bolt.

      Fig 20: Measuring Length Of Bolts From Seat To End

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7. Place the No. 1 and No. 2 balance shafts onto the crankcase.
8. Lay a strip of Plastigage across each journal.
   Fig 21: Identifying Plastigage Across Each Journal

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9. Install the balance shaft housing.
10. Apply a light coat of engine oil on the threads and under the heads of the bolts.
11. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

    Torque: 21.6 N*m (220 kgf*cm, 16 ft.*lbf) 

    Fig 22: Identifying Bolts In Sequence

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12. Mark the front of the bolts with paint.
Fig 23: Identifying O-Ring
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13. Retighten the bolts 90°.
14. Check that the paint mark is now at a 90° angle to the front.
15. Remove the balance shaft housing from the crankcase.
16. Measure the Plastigage at its widest point.

    Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 in.) 

    Maximum oil clearance: 0.049 mm (0.0019 in.) 

    NOTE: Remove the Plastigage completely after the measurement.

    If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft.

    HINT:

    If replacing a bearing, select a new one with the same number.

    Standard balance shaft housing journal bore diameter 

    STANDARD BALANCE SHAFT HOUSING JOURNAL BORE DIAMETER
    
    

    Item	Specified Condition
    Mark 1	26.000 to 26.006 mm (1.0236 to 1.0239 in.)
    Mark 2	26.007 to 26.012 mm (1.0239 to 1.0214 in.)
    Mark 3	26.013 to 26.018 mm (1.0241 to 1.0243 in.)

    Standard balance shaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.) 

    Standard bearing center wall thickness 

    STANDARD BEARING CENTER WALL THICKNESS
    
    

    Item	Specified Condition
    Mark 1	1.486 to 1.489 mm (0.05850 to 0.05862 in.)
    Mark 2	1.490 to 1.492 mm (0.05866 to 0.05874 in.)
    Mark 3	1.493 to 1.495 mm (0.0585 to 0.0586 in.)

1. Using a knife, cut off the lip of the oil seal.
2. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
   NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
   Fig 26: Removing Engine Rear Oil Seal

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1. Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
   Fig 27: Identifying Stiffening Crankcase Assembly Bolts In Sequence

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2. Remove the crankcase by prying the portions between the crankcase and cylinder block.
   NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder bock.
   Fig 28: Removing Crankcase By Prying Between Crankcase And Cylinder Block

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3. Remove the O-ring from the cylinder block.
   Fig 29: Identifying O-Ring From Cylinder Block

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

   Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.) 

   Maximum thrust clearance: 0.362 mm (0.0143 in.) 

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

   Fig 30: Measuring Connecting Rod Thrust Clearance

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1. Using marking paint, write the matched cylinder number on each connecting rod and cap.

   HINT:

   The matchmarks in the connecting rods and caps are for ensuring correct reassembly.

   Fig 31: Identifying Matchmark Cylinder Number On Each Connecting Rod And Cap

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2. Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
3. Clean the crank pin and bearing.
4. Check the crank pin and bearing for pitting and scratches.
   Fig 32: Identifying Connecting Rod Cap Bolts

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5. Lay a strip of Plastigage on the crank pin.
   Fig 33: Laying Plastigage On Crank Pin

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6. Check that the front mark of the connecting rod cap is facing in the correct direction.
7. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
8. Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.

   Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

   Fig 34: Checking Front Mark Of Connecting Rod Cap

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9. Mark the front of the connecting rod bolts with paint.
10. Retighten the cap bolts 90° as shown in the illustration.
11. Check that the crankshaft turns smoothly.
12. Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
    Fig 35: Retightening Connecting Rod Bolts By 90°

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13. Measure the Plastigage at its widest point.

    Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.) 

    Maximum oil clearance: 0.08 mm (0.0032 in.) 

    Fig 36: Measuring Plastigage

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    NOTE: Remove the Plastigage completely after the measurement.

    If the oil clearance is greater than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft.

    HINT:

    If replacing a bearing, select a new one with the same number as marked on the connecting rod.

    There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

    Standard connecting rod large end bore diameter 

    STANDARD CONNECTING ROD LARGE END BORE DIAMETER
    
    

    Mark	Specified Condition
    Mark 1	51.000 to 51.007 mm (2.0079 to 2.0082 in.)
    Mark 2	51.008 to 51.013 mm (2.0082 to 2.0084 in.)
    Mark 3	51.014 to 51.020 mm (2.0084 to 2.0087 in.)

    Standard connecting rod bearing thickness 

    STANDARD CONNECTING ROD BEARING THICKNESS
    
    

    Mark	Specified Condition
    Mark 1	1.485 to 1.488 mm (0.0585 to 0.0586 in.)
    Mark 2	1.489 to 1.491 mm (0.0586 to 0.0587 in.)
    Mark 3	1.492 to 1.494 mm (0.0587 to 0.0588 in.)

    Standard crankshaft pin diameter: 47.990 to 48.000 (1.8894 to 1.8898 in.) 

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
   Fig 37: Removing Carbon From Top Of Cylinder

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2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

   HINT:

   • Keep the bearing, connecting rod and cap together.
   • Arrange the piston and connecting rod assemblies in the correct order.

1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the oil ring and expander by hand.
   Fig 38: Removing Piston Ring Set

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1. Using a small screwdriver, pry out the 2 snap rings.
   Fig 39: Removing Piston Pin Hole Snap Ring

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1. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
   Fig 40: Heating Piston

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

   HINT:

   • The piston and pin are a matched set.
   • Arrange the piston, pin, ring, connecting rod and bearings in the correct order.
     Fig 41: Tapping Out Piston Pin

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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 (0.0016 to 0.0095 in.) 

   Maximum thrust clearance: 0.30 mm (0.012 in.) 

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

   Fig 42: Inspecting Crankshaft Thrust Clearance

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   HINT:

   The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the figure below.
2. Remove the 5 bearing caps from the cylinder block.

   HINT:

   • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.
   • Arrange the bearing caps in correct order.
3. Remove the crankshaft.

   HINT:

   Keep the crankshaft bearings and crankshaft thrust washer uppers together with the cylinder block.

   Fig 43: Identifying Bearing Cap Bolts In Sequence

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4. Clean each main journal and bearing.
5. Check each main journal and bearing for pitting and scratches.
   • If the journal or bearing is damaged, replace the bearings.
   • If necessary, replace the crankshaft.
6. Place the crankshaft onto the cylinder block.
7. Lay a strip of Plastigage across each journal.
   Fig 44: Laying Strip Of Plastigage Across Each Journal

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8. Examine the front marks and numbers, and install the bearing caps onto the cylinder block in the order shown in the figure below.
   Fig 45: Installing Bearing Caps Onto Cylinder Block

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9. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.
10. Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.

    Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

    Fig 46: Identifying Bearing Cap Bolts In Sequence

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11. Mark the front of the bearing cap bolts with paint.
12. Retighten the 10 bearing cap bolts by 90°.
    Fig 47: Retightening Bearing Cap Bolts By 90°

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13. Check that the paint marks are at a 90° angle to the front.
14. Remove the crankshaft bearing caps.
    Fig 48: Identifying Crankshaft Bearing Caps

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15. Measure the Plastigage at its widest point.

    Standard oil clearance: 0.008 to 0.024 mm (0.0003 to 0.0010 in.) 

    Maximum oil clearance: 0.050 mm (0.0020 in.) 

    NOTE: Remove the Plastigage completely after the measurement.

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

    HINT:

    If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft (see IMPRINTED NUMBERS ). Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

    IMPRINTED NUMBERS
    
    

    Cylinder block + Crankshaft	0 to 2	3 to 5	6 to 8	9 to 11
    Use bearing	"1"	"2"	"3"	"4"

    Fig 49: Identifying Location Of Imprinted Numbers

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    EXAMPLE

    • Imprinted number on the cylinder block is 3.
    • Imprinted number on the crankshaft is 4.

    3 + 4 = 7

    Select the bearing marked "3".

    Standard cylinder block journal bore diameter 

    STANDARD CYLINDER BLOCK JOURNAL BORE DIAMETER
    
    

    Mark	Specified Condition
    0	59.000 to 59.002 mm (2.3228 to 2.3229 in.)
    1	59.003 to 59.004 mm (2.3230 to 2.3230 in.)
    2	59.005 to 59.006 mm (2.3230 to 2.3231 in.)
    3	59.007 to 59.009 mm (2.3231 to 2.3232 in.)
    4	59.010 to 59.011 mm (2.3232 to 2.3233 in.)
    5	59.012 to 59.013 mm (2.3233 to 2.3234 in.)
    6	59.014 to 59.016 mm (2.3234 to 2.3235 in.)

    Standard crankshaft journal diameter 

    STANDARD CRANKSHAFT JOURNAL DIAMETER
    
    

    Mark	Specified Condition
    0	54.999 to 55.000 mm (2.1653 to 2.1654 in.)
    1	54.997 to 54.998 mm (2.1652 to 2.1653 in.)
    2	54.995 to 54.996 mm (2.1652 to 2.1652 in.)
    3	54.993 to 54.994 mm (2.1651 to 2.1651 in.)
    4	54.991 to 54.992 mm (2.1650 to 2.1650 in.)
    5	54.988 to 54.990 mm (2.1649 to 2.1650 in.)

    Standard bearing center wall thickness 

    BEARING CENTER WALL THICKNESS (STANDARD)
    
    

    Mark	Specified Condition
    1	1.993 to 1.996 mm (0.0785 to 0.0786 in.)
    2	1.997 to 1.999 mm (0.0786 to 0.0787 in.)
    3	2.000 to 2.002 mm (0.0787 to 0.0788 in.)
    4	2.003 to 2.005 mm (0.0789 to 0.0789 in.)

1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the figure below.
2. Remove the 5 bearing caps from the cylinder block.
3. Remove the crankshaft from the cylinder block.
   Fig 50: Identifying Bearing Cap Bolts In Sequence

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HINT:

Arrange the bearings in the correct order.

Fig 52: Identifying Crankshaft Bearing

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HINT:

Arrange the bearings in the correct order.

Fig 53: Identifying No. 2 Crankshaft Bearing

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1. Remove the 4 bolts and 4 oil nozzles.
   Fig 54: Identifying Oil Nozzle Sub-Assembly

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