Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Cylinder Block: Disassembly
- INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
- REMOVE GENERATOR
Remove the bolt, nut, pipe bracket and generator.
- REMOVE TIMING BELT AND PULLEYS (See REMOVAL )
- REMOVE NO.2 WATER BYPASS PIPE WITH HOSE
Remove the bolt, 2 nuts, water bypass pipe and gasket.
- REMOVE WATER PUMP
Remove the 6 bolts, water pump and O-ring.
- REMOVE CYLINDER HEAD (See REMOVAL )
- REMOVE OIL PRESSURE SWITCH (See OIL AND FILTER ) AND KNOCK SENSORS (See BASIC DIAGNOSTIC PROCEDURES )
- REMOVE OIL FILTER AND BRACKET ASSEMBLY
- Remove the union bolt and oil filter bracket.
- Remove the gasket from the union bolt.
- Remove the O-ring from the oil filter bracket.
- REMOVE NO. 1 OIL PIPE
Remove the union bolt, oil pipe and 2 gaskets.
- REMOVE FUEL INLET PIPE
Remove the 2 bolts and fuel inlet pipe.
- REMOVE LH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
- REMOVE RH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
- REMOVE OIL PUMP (See REMOVAL )
- REMOVE REAR OIL SEAL RETAINER
- Remove the 6 bolts of the retainer.
- Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver.
- CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rods back and forth.
- Standard thrust clearance: 0.250 - 0.402 mm (0.0098 - 0.0158 in.)
- Maximum thrust clearance: 0.50 mm (0.0197 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
- Connecting rod thickness: 25.898 - 25.950 mm (1.0196 - 1.0217 in.)
- REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
- Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
- Remove the connecting rod cap bolts.
- Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
- Clean the crank pin and bearings.
- 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.
- Lay a strip of Plastigage across the crank pin.
- Install the connecting rod cap with the 2 bolts (See REASSEMBLY ).
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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