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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