Disassembly [11/2022 - ]: Procedure
- REMOVE NO. 1 VENTILATION CASE WARNING:
Do not disassembly except if the No. 1 ventilation case to be damaged.
- INSPECT CONNECTING ROD THRUST CLEARANCE
- Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.
Standard Thrust Clearance
0.160 to 0.512 mm (0.00630 to 0.0202 in.)
Maximum Thrust Clearance
0.512 mm (0.0202 in.)
HINT:
If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.
- Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.
- INSPECT CONNECTING ROD OIL CLEARANCE
*a Alignment Mark - - - Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
- Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.
- Clean the crank pin and connecting rod bearing.NOTE:
Check the crank pin and connecting rod bearing for pitting and scratches.
HINT:
If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.
- Check the crank pin and connecting rod bearing for pitting and scratches.
HINT:
If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.
*a Plastigage *b Front Mark *c Paint Mark *d 90° *e 1, 2 or 3 Mark - - Front of Engine - - - Lay a strip of Plastigage on the crank pin.
- Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.
- Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
- Using an E12 "TORX" socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
- Mark the front of each connecting rod bolt with paint.
- Tighten the connecting rod bolts 90° as shown in the illustration.NOTE:
Do not turn the crankshaft during the measurement.
- Remove the 2 connecting rod bolts and connecting rod cap.
HINT:
Keep the connecting rod bearing and connecting rod cap together.
- Measure the Plastigage at its widest point.
Standard Oil Clearance
0.032 to 0.065 mm (0.00126 to 0.00256 in.)
Maximum Oil Clearance
0.065 mm (0.00256 in.)
HINT:
- If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.
- If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.
Standard Connecting Rod Big End Inside Diameter
Mark Specified Condition 1 51.000 to 51.008 mm (2.00787 to 2.00818 in.) 2 51.008 to 51.016 mm (2.00818 to 2.00850 in.) 3 51.016 to 51.024 mm (2.00850 to 2.00881 in.) Standard Connecting Rod Bearing Center Wall Thickness
Mark Specified Condition 1 1.483 to 1.487 mm (0.05839 to 0.05854 in.) 2 1.487 to 1.491 mm (0.05854 to 0.05870 in.) 3 1.491 to 1.495 mm (0.05870 to 0.05886 in.) Standard Crank Pin Diameter
47.992 to 48.000 mm (1.88945 to 1.88976 in.)
NOTE:Remove the Plastigage completely after the measurement.
- Perform the inspection above for each cylinder.
- REMOVE PISTON WITH CONNECTING ROD
- Using a ridge reamer, remove all the carbon from the top of each cylinder.
- Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.
- Push the 4 pistons, 4 connecting rods and 4 connecting rod bearings out through the top of the cylinder block sub-assembly.
HINT:
- Keep the connecting rod bearings, connecting rods and connecting rod caps together.
- Arrange the removed parts in such a way that they can be reinstalled to their original locations.
- REMOVE CONNECTING ROD BEARING
- INSPECT CRANKSHAFT THRUST CLEARANCE
- Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard Thrust Clearance
0.02 to 0.22 mm (0.000787 to 0.00866 in.)
Maximum Thrust Clearance
0.22 mm (0.00866 in.)
HINT:
If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.
Standard Thrust Washer Thickness
2.415 to 2.470 mm (0.0951 to 0.0972 in.)
- Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
- REMOVE CRANKSHAFT BEARING CAP
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- Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
- Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps from the cylinder block sub-assembly by wiggling each crankshaft bearing cap back and forth.
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- REMOVE CRANKSHAFT
- REMOVE CRANKSHAFT THRUST WASHER
- REMOVE CRANKSHAFT BEARING
- REMOVE PISTON RING SET
- Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
- Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.
HINT:
Arrange the removed parts in such a way that they can be reinstalled to their original locations.
- REMOVE PISTON PIN
- Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.
HINT:
Tape the screwdriver tip before use.
- Gradually heat each piston to between 80 and 90°C (176 and 194°F).WARNING:
Be sure to wear protective gloves.
- Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.
HINT:
- The piston and piston pin are a matched set.
- Arrange the removed parts in such a way that they can be reinstalled to their original locations.
- Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.
- REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
- REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY
- REMOVE RING PIN
- REMOVE STRAIGHT PIN