4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES 82E-5 – 98E-5 SERIES 4-11 Step Removal Parts Remarks 23 1) Remove main bearing cap bolt. While shaking main bearing cap, remove main bearing cap together with lower main bearing metal. 2) Extract crankshaft, taking care not to damage it. 3) Remove upper main bearing metal. 1) Before extracting crankshaft, measure the side gap around it. Apply a dial gauge to the end of crankshaft. Force the crankshaft on both sides in the axial direction to measure the thrust gap. Alterna- tively, insert a thickness gauge directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap.
If the limit size is exceeded, replace the thrust metal with a new one. Thrust gap (All models) 2) Notice on the removal of thrust metal. (a) When removing thrust metal, ascertain the position and direction where thrust metal is installed in relation to the cap. (b) Make sure that the thrust metal groove is outward in relation to the cap. 24 1) Remove piston and connecting rod assembly. 1) To selectively remove a desired piston and connecting rod assembly without extracting crankshaft, take the steps itemized below: (a) Remove carbon deposits from the upper wall of the cylinder using fine sandpaper, taking care not to damage the inner sur- face of the cylinder.
(b) While turning the crankshaft, with the con- necting rod cap removed, raise the piston up to the top dead center (TDC). (c) Extract the piston/connecting rod assem- bly while tapping the connecting rod at the large end with the handle of a plastic ham- mer or the like. 25 1) Remove tappet.