M20C-FKS ENGINE MECHANICAL  CYLINDER BLOCK  DISASSEMBLY  

Remove the 4 bolts and No. 1 ventilation case from the cylinder block sub-assembly.

Remove the 3 oil separator gaskets from the No. 1 ventilation case.

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.

0.708,0.615 0.979,0.26 true 1,0.094 1.302,0.313 0.302,0.219 10 false *a

*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.

HINT:

Keep the connecting rod bearing and connecting rod cap together.

1.635,0.615 0.813,0.458 true 0.635,0.344 0.948,0.563 0.313,0.219 10 false *a

*a	Plastigage

Lay a strip of Plastigage on the crank pin.

1.521,0.833 0.802,0.615 true 0.625,0.5 0.875,0.781 0.25,0.281 10 false *a

*a	Front Mark

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.

2.26,0.802 2.531,0.385 2.531,0.385 2.677,0.385 false 1.396,0.479 1.854,0.677 0.458,0.198 10 false *b 2.729,0.281 3.042,0.479 0.313,0.198 10 false *a

*a	Paint Mark
*b	90°
	Front of Engine

Mark the front of each connecting rod bolt with paint.

1.677,0.969 0.969,0.667 true 1.375,3.167 0.719,3.615 0.719,3.615 1.26,4.208 true 1.385,3.615 0.74,3.615 true 0.802,0.542 1.083,0.708 0.281,0.167 10 false *a 0.542,3.573 0.854,3.729 0.313,0.156 10 false *b

*a	Plastigage
*b	1, 2 or 3 Mark

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 (0.058386 to 0.058543 in.)
2	1.487 to 1.491 mm (0.058543 to 0.058701 in.)
3	1.491 to 1.495 mm (0.058701 to 0.058858 in.)

Standard Crank Pin Diameter:

47.992 to 48.000 mm (1.88945 to 1.88976 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

1.333,1.094 1.552,1.042 false 1.583,0.938 1.896,1.094 0.313,0.156 10 false *a

*a	Ridge Reamer

Using a ridge reamer, remove all the carbon from the top of each cylinder.

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.)

1.375,1.313 1.531,1.51 0.156,0.198 10 false 1 0.677,0.302 0.833,0.5 0.156,0.198 10 true 4 1.75,0.281 1.948,0.448 0.198,0.167 10 true 10 1.229,0.302 1.385,0.458 0.156,0.156 10 true 8 0.667,1.896 0.823,2.094 0.156,0.198 10 true 3 1.219,1.885 1.375,2.083 0.156,0.198 10 true 7 1.802,1.896 1.958,2.094 0.156,0.198 10 true 9 2.354,1.885 2.51,2.083 0.156,0.198 10 true 5 2.917,1.896 3.073,2.063 0.156,0.167 10 true 1 2.917,0.313 3.073,0.49 0.156,0.177 10 true 2 2.354,0.313 2.531,0.469 0.177,0.156 10 true 6

Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.

1.115,1.76 1.115,1.531 1.115,1.531 1.354,1.281 false 1.063,1.802 1.375,2 0.313,0.198 10 false *a

*a	Piston Ring Expander

Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.

1.885,0.979 2.208,1.188 true 2.104,0.813 2.313,0.375 true 2.25,1.115 2.563,1.271 0.313,0.156 10 false *a 2.344,0.271 2.656,0.427 0.313,0.156 10 false *b

*a	Front Mark Cutout Portion
*b	Protective Tape

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 to 194°F).

CAUTION:

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 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.

Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.