Engine Mechanical Cylinder Block: Disassembly

1. Disconnect the wire clamp (for knock sensor 1, 2) from the bracket of the water bypass pipe.
   Fig 1: Disconnecting Wire Clamp From Bracket

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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.

1. Remove the 2 bolts and the engine wire cover from the LH side of the cylinder block.
   Fig 2: Removing Engine Wire Cover From LH Side

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2. Remove the bolt, disconnect the bracket on the engine wire from the cylinder block.

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

Fig 3: Disconnecting Brackets On Engine Wire From Cylinder Block (RH)

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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.
   Fig 4: Removing Rear Oil Seal Retainer Bolts

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

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.) 

Fig 5: Measuring Connecting Rod Thrust Clearance

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

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

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 & Lower Bearing By Wiggling

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   NOTE: 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.
8. Remove the 2 bolts, the connecting rod cap and the lower bearing. (See procedure ( b) and ( c) above)
   Fig 9: Connecting Rod Cap & Lower Bearing Bolts

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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: Number Mark Table

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   Fig 12: Locating Number Marks

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   Reference 

   CONNECTING ROD BIG END INSIDE DIAMETER
   
   

   Mark	Specification
   Mark "1"	55.000 - 55.006 mm (2.1654 - 2.1656 in.)
   Mark "2"	55.006 - 55.012 mm (2.1656 - 2.1658 in.)
   Mark "3"	55.012 - 55.018 mm (2.1658 - 2.1661 in.)
   Mark "4"	55.018 - 55.024 mm (2.1661 - 2.1663 in.)

   CRANKSHAFT CRANK PIN DIAMETER
   
   

   Mark	Specification
   Mark "1"	51.994 - 52.000 mm (2.0470 - 2.0472 in.)
   Mark "2"	51.988 - 51.994 mm (2.0468 - 2.0470 in.)
   Mark "3"	51.982 - 51.988 mm (2.0465 - 2.0468 in.)

   STANDARD SIZED BEARING CENTER WALL THICKNESS
   
   

   Mark	Specification
   Mark "2"	1.484 - 1.487 mm (0.0584 - 0.0585 in.)
   Mark "3"	1.487 - 1.490 mm (0.0585 - 0.0587 in.)
   Mark "4"	1.490 - 1.493 mm (0.0587 - 0.0588 in.)
   Mark "5"	1.493 - 1.496 mm (0.0588 - 0.0589 in.)
   Mark "6"	1.496 - 1.499 mm (0.0589 - 0.0590 in.)
   Mark "7"	1.499 - 1.502 mm (0.0590 - 0.0591 in.)

10. Completely remove the plastigage.

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
   Fig 13: Removing All 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.) 

Fig 14: Measuring Crankshaft Thrust Clearance

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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.) 

1. Evenly loosen and remove the 10 main bearing cap bolts a little at time for several times, in the sequence shown.
   Fig 15: Removing Main Bearing Cap Bolts In 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).
   Fig 16: Prying & Removing Bearing Cap With Screwdrivers

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   NOTE: Be careful not to damage the cylinder block.
   NOTE:

   • Keep the lower bearing and the main bearing cap together.
   • Arrange the main bearing caps and lower thrust washers in correct order.
3. Lift out the crankshaft.
   NOTE: 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 17: Laying Strip Of Plastigage Across Each Journal

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8. Install the main bearing caps. (See REASSEMBLY )
   Fig 18: Installing Main Bearing Caps

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   NOTE: Do not turn the crankshaft.
9. Remove the main bearing caps. (See procedure ( a) and ( b) above)
10. Measure the plastigage at its widest point.
    1. Standard clearance: 0.040 - 0.058 mm (0.0016 - 0.0023 in.) Maximum clearance: 0.070 mm (0.0028 in.) 

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

    Fig 19: Measuring Plastigage Widest Point

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    NOTE: 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 the table below 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".
    Fig 20: Bearing Position Identification For No. 1 & No. 5.

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    Fig 21: Identifying Number Mark Of Cylinder Block, Crank Shaft & Bearing

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    Others: 

    Fig 22: Bearing Position Identification Table For No. 1 & No. 5

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    Reference 

    CYLINDER BLOCK MAIN JOURNAL BORE DIAMETER (A)
    
    

    Mark	Size
    Mark "00"	72.000 mm (2.8346 in.)
    Mark "01"	72.001 mm (2.8347 in.)
    Mark "02"	72.002 mm (2.8347 in.)
    Mark "03"	72.003 mm (2.8348 in.)
    Mark "04"	72.004 mm (2.8348 in.)
    Mark "05"	72.005 mm (2.8348 in.)
    Mark "06"	72.006 mm (2.8349 in.)
    Mark "07"	72.007 mm (2.8349 in.)
    Mark "08"	72.008 mm (2.8350 in.)
    Mark "09"	72.009 mm (2.8350 in.)
    Mark "10"	72.010 mm (2.8350 in.)
    Mark"11"	72.011 mm (2.8351 in.)
    Mark "12"	72.012 mm (2.8351 in.)
    Mark "13"	72.013 mm (2.8352 in.)
    Mark "14"	72.014 mm (2.8352 in.)
    Mark "15"	72.015 mm (2.8352 in.)
    Mark "16"	72.016 mm (2.8353 in.)

    CRANKSHAFT MAIN JOURNAL DIAMETER (B)
    
    

    Mark	Size
    Mark "00"	67.000 mm (2.6378 in.)
    Mark "01"	66.999 mm (2.6378 in.)
    Mark "02"	66.998 mm (2.6377 in.)
    Mark "03"	66.997 mm (2.6377 in.)
    Mark "04"	66.996 mm (2.6376 in.)
    Mark "05"	66.995 mm (2.6376 in.)
    Mark "06"	66.994 mm (2.6376 in.)
    Mark "07"	66.993 mm (2.6375 in.)
    Mark "08"	66.992 mm (2.6375 in.)
    Mark "09"	66.991 mm (2.6374 in.)
    Mark "10"	66.990 mm (2.6374 in.)
    Mark "11"	66.989 mm (2.6374 in.)
    Mark "12"	66.988 mm (2.6373 in.)

    STANDARD BEARING CENTER WALL THICKNESS: No. 1 & No. 5
    
    

    Mark	Size
    Mark "3"	2.481 - 2.484 mm (0.0977 - 0.0978 in.)
    Mark "4"	2.484 - 2.487 mm (0.0978 - 0.0979 in.)
    Mark "5"	2.487 - 2.490 mm (0.0979 - 0.0980 in.)
    Mark "6"	2.490 - 2.493 mm (0.0980 - 0.0981 in.)
    Mark "7"	2.493 - 2.496 mm (0.0981 - 0.0983 in.)

    STANDARD BEARING CENTER WALL THICKNESS: OTHERS
    
    

    Mark	Size
    Mark "1"	2.481 - 2.484 mm (0.0977 - 0.0978 in.)
    Mark "2"	2.484 - 2.487 mm (0.0978 - 0.0979 in.)
    Mark "3"	2.487 - 2.490 mm (0.0979 - 0.0980 in.)
    Mark "4"	2.490 - 2.493 mm (0.0980 - 0.0981 in.)
    Mark "5"	2.493 - 2.496 mm (0.0981 - 0.0983 in.)

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.

Fig 23: Checking Fit Between Piston & Piston Pin

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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.

1. Using a piston ring expander, remove the 2 compression rings.
   Fig 24: Removing Compression Rings Using Piston Ring Expander

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2. Remove the 2 side rails and the oil ring by hand.

1. Using a small screwdriver, pry out the 2 snap rings.
   Fig 25: Prying Out Snap Rings Using Small Screwdriver

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2. Gradually heat the piston to approx. 60°C (140°F).
   Fig 26: Heating Piston

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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 27: Tapping Out Piston Pin & Pin

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