Engine Block Disassembly

ENGINE BLOCK

COMPONENTS:

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 misconnection. Inspection the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center

1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove cylinder head.
6. Remove oil pump.
7. Remove oil filter assembly.

8. Remove A/C compressor (A) from engine.

9. Remove alternator (A) from engine.

10. Remove power steering pump (A) from engine.

DISASSEMBLY
1. Remove drive plate.

2. Remove knock sensor (A).

3. Remove upper oil pan (A).

4. Remove baffle plate (A).

5. Remove rear oil seal case (A).

6. Remove oil drain cover (A).
7. Check the connecting rod end play.
8. Check the connecting rod oil clearance.
9. Remove 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 top 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 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 piston rings.
1) Using a piston ring expender, 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.