Cylinder Block: Disassembly

1. Disconnect the wire clamp (for knock sensor 1,2) from the bracket of the water bypass pipe.
2. Remove the bolt.
3. Pull out the water bypass pipe from the water pump.
4. Remove the O-ring from the water bypass pipe.
Fig 1: Removing O-Ring From Water Bypass Pipe
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1. Remove the 2 bolts and the engine wire cover from the LH side of the cylinder block.
2. Remove the bolt, disconnect the bracket on the engine wire from the cylinder block.

Fig 2: Removing Bolts & Engine Wire Cover From LH Side Of Cylinder Block

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Remove the 2 bolts, and disconnect the 2 brackets on the engine wire from the cylinder block.

Remove the bolt and bracket.

Remove the 4 bolts and the mounting bracket. Remove the 2 mounting brackets

Remove the 2 drain unions.

1. Remove the 7 bolts.
2. Using a screwdriver, ply off the oil seal retainer and the main bearing cap with a screwdriver.
3. Remove the O-ring.

Fig 4: Removing Rear Oil Seal Retainer & Bolt

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

1. Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 in.) 
2. Maximum thrust clearance: 0.35 mm (0.0138 in.) 

If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

1. Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 in.) 

Fig 5: Measuring Thrust Clearance Using Dial Indicator

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1. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
   Fig 6: Removing Connecting Rod Cap Bolts

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3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and the lower bearing by wiggling the connecting rod cap right and left.
   Fig 7: Removing Connecting Rod Cap

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   HINT:

   Keep the lower bearing inserted with the connecting rod cap.

4. Clean the crank pin and the bearing.
5. Check the crank pin and the bearing for pitting and scratches.

   If the crank pin or the bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

6. Lay a strip of plastigage across the crank pin.
   Fig 8: Laying Strip Of Plastigage Across Crank Pin

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7. Install the connecting rod cap with the 2 bolts. (See REASSEMBLY )
   NOTE: Do not turn the crankshaft. 
Fig 9: Installing Connecting Rod Cap With Bolts
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8. Remove the 2 bolts, the connecting rod cap and the lower bearing. (See procedure ( b) and ( c) above)
9. Measure the plastigage at its widest point.
   1. Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 in.) 
   2. Maximum oil clearance: 0.065 mm (0.0026 in.) 

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

   Fig 10: Measuring Plastigage At Widest Point

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   HINT:

   If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the connecting rod cap and the crankshaft, then select the one with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".

   Fig 11: Standard Bearing Replacement

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   Fig 12: Determining Standard Bearing Number Table

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   1. EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")

   Reference Connecting rod big end inside diameter. 

   Fig 13: Reference Connecting Rod Big End Inside Diameter Table

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   Crankshaft crank pin diameter: 

   Fig 14: Crankshaft Crank Pin Diameter Table

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   Standard sized bearing center wall thickness: 

   Fig 15: Standard Sized Bearing Center Wall Thickness Table

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10. Completely remove the plastigage.

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
Fig 16: Removing Carbon From Top Of Cylinder Using Ridge Reamer
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2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:

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

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

1. Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.) 
2. Maximum thrust clearance: 0.30 mm (0.0118 in.) 

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

1. Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 in.) 

Fig 17: Measuring Thrust Clearance While Prying Crankshaft Back & Forth Using Screwdriver

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1. Evenly loosen and remove the 10 main bearing cap bolts a little at a time for several times, in the sequence shown in Fig 18 .
   Fig 18: Identifying Bearing Cap Removing Sequence

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2. Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, the 5 lower bearings and the 2 lower thrust washers (No. 3 main bearing cap only).
   NOTE: Be careful not to damage the cylinder block. 

   HINT:

   • Keep the lower bearing and main bearing cap together.
   • Arrange the main bearing caps and lower thrust washers in correct order.
   Fig 19: Prying Out Main Bearing Cap

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3. Lift out the crankshaft.

   HINT:

   Keep the upper bearings and the upper thrust washers together with the cylinder block.

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 on the cylinder block.
7. Lay a strip of plastigage across each journal.
   Fig 20: Laying Strip Of Plastigage Across Journal

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8. Install the main bearing caps. (See REASSEMBLY )
   NOTE: Do not turn the crankshaft. 
Fig 21: Identifying Bearing Cap Installing Sequence
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9. Remove the main bearing caps. (See procedure ( a) and ( b) above)
10. Measure the plastigage at its widest point.
    Fig 22: Measuring Plastigage At Widest Point

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    1. Standard clearance: 0.040 - 0.058 mm (0.0016 - 0.0023 in.) 
    2. Maximum clearance: 0.070 mm (0.0028 in.) 
    Fig 23: Identifying Bearing Marks

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

    HINT:

    If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the cylinder block and the crankshaft, then refer to Fig 24 and Fig 25 for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1", "2", "3", "4" and "5".

    No. 1, No. 5: 

    Fig 24: No. 1 & No. 5 Bearing Table

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    1. EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5")

    Others: 

    Fig 25: Others Bearing Table

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    1. EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3")

    Reference Cylinder block main Journal bore diameter (A): 

    Fig 26: Cylinder Block Main Journal Bore Diameter (A) Table (1 Of 2)

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    Fig 27: Cylinder Block Main Journal Bore Diameter (A) Table (2 Of 2)

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    Crankshaft main Journal diameter (B): 

    Fig 28: Crankshaft Main Journal Diameter (B) Table

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    Standard bearing center wall thickness: No. 1 and No. 5 

    Fig 29: Standard Bearing Center Wall Thickness No. 1 & No. 5 Table

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    Others: 

    Fig 30: Standard Bearing Center Wall Thickness Others Table

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11. Completely remove the Plastigage.

1. Lift up the crankshaft.
2. Remove the 5 upper main bearings and the 2 upper thrust washers from the cylinder block.

   HINT:

   Arrange the main bearing caps, bearings and thrust washers in correct order installation.

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.

Fig 31: Checking Fit Between Piston & Piston Pin

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1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and the oil ring by hand.

   HINT:

   Arrange the piston rings in correct order installation.

Fig 32: Removing Compression Rings Using Piston Ring Expander

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1. Using a small screwdriver, pry out the 2 snap rings.
   Fig 33: Prying Out Snap Rings Using Screwdriver

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2. Gradually heat the piston to approx. 60°C (140°F).
   Fig 34: Heating Piston To 60°C (140°F)

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3. Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and the pin and remove the connecting rod.
   Fig 35: Lightly Tapping Out Piston Pin Using Hammer

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   HINT:

   • The piston and the pin are a matched set.
   • Arrange the pistons, the pins, rings, the connecting rods and the bearings in correct order for installation.