DISASSEMBLY EM67 EM9Q0. INSTALL ENGINE TO ENGINE STAND FOR DIS- ASSEMBLY. REMOVE CYLINDER HEAD (See page EM9). REMOVE WATER BYPASS PIPE Remove the nuts, bolts, water bypass pipe and gasket.. REMOVE THERMOSTAT (See page CO). REMOVE KNOCK SENSOR 6. REMOVE ENGINE COOLANT DRAIN UNION 7. REMOVE OIL PUMP (See page LU8) A8 8. REMOVE OIL FILTER (See page LU) 9. REMOVE OIL FILTER UNION Using a mm hexagon wrench, remove the oil filter union. Oil Filter Union A0 0. REMOVE OIL PAN (a) Remove the bolts and nuts. A0 SST SST A06 (b) Insert the blade of SST between the bearing cap subassembly and oil pan, and cut off applied sealer and remove the oil pan. SST 0900000 Be careful not to the damage the oil pan contact surface of the bearing cap subassembly. Be careful not to damage the oil pan flange. 000 MR (RM760U) 609
EM68 ENGINE MECHANICAL. REMOVE OIL STRAINER Remove the nuts, bolt, oil strainer and gasket. A77 A0. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.60 0. mm (0.006 0.0 in.) Maximum thrust clearance: 0. mm (0.0 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 9.788 9.80 mm (0.779 0.78 in.). REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Remove the connecting rod cap bolts. A06 A07 (c) Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. 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. 000 MR (RM760U) 60
EM69 Plastigage (f) Lay a strip of Plastigage on the crank pin. A09 (g) Install the connecting rod cap with the bolts (See page EM8). Do not turn the crankshaft. (h) Remove the bolts, connecting rod cap and lower bearing (See procedure (b) and (c) above). A06 (i) Measure the Plastigage at its widest point. Standard oil clearance: 0.08 0.060 mm (0.00 0.00 in.) Maximum oil clearance: 0.08 mm (0.00 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. A060 Mark, or If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are sizes of standard bearings, marked, and accordingly. Reference Standard bearing center wall thickness: Mark, or A098 (j) Mark.86.90 mm (0.08 0.087 in.) Mark.90.9 mm (0.087 0.088 in.) Mark.9.98 mm (0.088 0.090 in.) Completely remove the Plastigage. 000 MR (RM760U) 6
EM70 ENGINE MECHANICAL 7 9 6 7 9 6 0 8 A066. REMOVE PISTON AND CONNECTING ROD AS- SEMBLIES (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. Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.. REMOVE BEARING CAP SUBASSEMBLY AND CRANKSHAFT REAR OIL SEAL, AND CHECK OIL CLEARANCE (a) Remove the 0 hexagon head bearing cap bolts. (b) Uniformly loosen and remove the 0 bearing cap bolts in several passes, in the sequence shown. 0 8 A00 A09 (c) Using a screwdriver, remove the bearing cap subassembly by prying the portions between the cylinder block and bearing cap subassembly. Remove the lower main bearings. Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly. Keep the lower bearing and bearing cap subassembly together. (d) Remove the crankshaft rear oil seal. (e) Lift out the crankshaft. Keep the upper bearings together with the cylinder block. (f) Clean each main journal and bearing. (g) Check each main journal, bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Plastigage (h) (i) Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. A00 000 MR (RM760U) 6
EM7 8 7 6 0 9 A00 (j) Install the bearing cap subassembly (See page EM8). Do not turn the crankshaft. (k) Remove the bearing cap subassembly (See procedures (a) to (d) above). (l) Measure the Plastigage at its widest point. Standard oil clearance: 0.0 0.0 mm (0.0006 0.00 in.) Maximum oil clearance: 0.00 mm (0.000 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. A000 No. No. No. No. No. No. Mark 0,,,,, or 6 No. No. No. Mark 0,,,, or Total number : Number mark No. (m) 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 sizes of standard bearings, marked,, and accordingly. Cylinder block (A) + Crankshaft (B) 0 6 8 9 Mark,, or Use bearing EXAMPLE: Cylinder block (A) + Crankshaft (B) = Total number 7 (Use bearing ) A097 000 MR (RM760U) 6
EM7 ENGINE MECHANICAL Standard bearings selection chart Cylinder block Number mark 0 Crankshaft number mark 0 6 EXAMPLE: Cylinder block, Crank shaft, Use bearing Reference Item Mark mm (in.) Cylinder block main journal bore diameter (A) 0 6 Crankshaft main journal diameter (B) 0 Standard bearing center wall thickness (n).000.00 (.07.07).00.00 (.07.07).00.007 (.07.07).007.00 (.07.076).00.0 (.076.077).0.0 (.077.078).0.06 (.078.079) 7.998 8.000 (.8897.8898) 7.996 7.998 (.8896.8897) 7.99 7.996 (.889.8896) 7.99 7.99 (.889.889) 7.990 7.99 (.889.889) 7.988 7.990 (.889.889).99.996 (0.078 0.0786).996.999 (0.0786 0.0787).999.00 (0.0787 0.0788).00.00 (0.0788 0.0789) Completely remove the Plastigage. A0 6. 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: 0.0 0. mm (0.006 0.009 in.) Maximum thrust clearance: 0.0 mm (0.08 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness:.0.80 mm (0.097 0.0976 in.) 7. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the upper main bearings and thrust washers from the cylinder block. Arrange the main bearings and thrust washers in the correct order. 000 MR (RM760U) 6
EM7 8. CHECK FIT BETWEEN PISTON AND PISTON PIN 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. A077 9. REMOVE PISTON RINGS (a) Using a piston ring expander, remove the compression rings. (b) Remove the side rails and oil ring by hand. Arrange the piston rings in the correct order only. A07 0. DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver, pry out the snap rings. A09 80 90 C (b) Gradually heat the piston to 80 90 C (76 9 F). A078 (c) Using a plasticfaced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod. The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A079 000 MR (RM760U) 6