Engine Block Disassembly
ENGINE BLOCKCOMPONENTS:
REMOVAL
CAUTION:
^ Use fender covers to avoid damaging painted surfaces.
^ To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
^ Mark all wiring and hoses to avoid mis-connection.
^ Inspect the timing belt before removing the cylinder head.
^ Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
^ Engine removal is required 1br this procedure.
1. Remove the exhaust manifold.
2. Remove the intake manifold.
3. Remove the timing chain.
4. Remove the water temperature control assembly.
5. Remove the cylinder head.
6. Remove the oil pump.
7. Remove the oil filter assembly.
8. Remove the A/C compressor (A) from engine.
9. Remove the alternator (A) from engine.
10. Remove the power steering pump from engine.
DISASSEMBLY
1. Remove the drive plate,
2. Remove the knock sensor (A).
3. Remove the upper oil pan (A).
4. Remove the baffle plate (A).
5. Remove the rear oil seal case (A).
6. Remove the oil drain cover (A).
7. Check the connecting rod end play.
8. Check the connecting rod cap oil clearance.
9. Remove the piston and connecting rod assemblies.
1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
2) Push the piston, connecting rod assembly and upper bearing through the JDP of the cylinder block.
NOTE:
^ Keep the bearings, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in the correct order.
10. Remove the crankshaft main bearing cap and check oil clearance.
11. Check the crankshaft end play.
12. Lift the crankshaft (A) out of engine, being careful not to damage journals.
NOTE: Arrange the main bearings and thrust bearings in the correct order.
13. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace piston and piston pin as a set.
14. Remove the piston rings.
1) Using a piston ring expander, remove the 2 compression rings.
2) Remove 2 side rails and the spacer by hand.
NOTE: Arrange the piston rings in the correct order only.
15. Disconnect connecting rod from piston.
Using a press, remove the piston pin from the piston. (Press-in load: 800 - 1400kg (1764 - 3086 lb)