Disassembly and Assembly
CYLINDER BLOCK
Disassembly and Assembly
DISASSEMBLY
1. Remove engine assembly from vehicle, and separate transmission from engine.
2. Remove engine mounting bracket.
3. Remove RH exhaust manifold.
4. Install engine sub-attachment (SST) to right side of cylinder block.
^ Use spacer to engine rear side.
5. Lift engine, and mount it onto the engine stand (SST).
^ A commercial engine stand can be used.
CAUTION: Use an engine stand that has a load capacity [approximately 220 kg (441 lbs.) or more] large enough for supporting the engine weight.
NOTE: This example is an engine stand for holding at transmission mounting side with the drive plate removed.
6. Drain engine oil and engine coolant from inside of engine.
7. Remove cylinder head.
8. Remove knock sensor.
CAUTION: Carefully handle the sensor avoiding shocks.
9. Remove drive plate with power tool. Fix crankshaft with a ring gear stopper [SST: KV1011770 (J44716)], and remove mounting bolts.
^ Loosen mounting bolts in diagonal order.
CAUTION:
^ Do not disassemble drive plate.
^ Never place the drive plate with signal plate facing down.
^ When handling signal plate, take care not to damage or scratch it.
^ Handle signal plate in a manner that prevents it from becoming magnetized.
10. Remove pilot converter using pilot bushing puller (SST) or suitable tool as necessary.
11. Use a seal cutter (SST) to cut away liquid gasket and remove rear oil seal retainer.
CAUTION:
^ Be careful not to damage mounting surface.
^ If rear oil seal retainer is removed, replace it with a new one.
NOTE: Rear oil seal and retainer make up a single part and are removed as an assembly.
12. Remove baffle plate from main bearing beam (2WD model).
13. Remove the piston and connecting rod assembly.
^ Before removing the piston and connecting rod assembly, check the connecting rod side clearance.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and connecting rod assembly out to the cylinder head side.
14. Remove the connecting rod bearings from connecting rod and connecting rod cap.
CAUTION: When removing them, note the installation position. Keep them in the correct order.
15. Remove the piston rings form the piston.
^ Use a piston ring expander (commercial service tool).
CAUTION:
^ When removing the piston rings, be careful not to damage the piston.
^ Be careful not to damage piston rings by expanding them excessively.
16. Remove the piston from the connecting rod as follows.
a. Using a snap ring pliers (commercial service tool), remove the snap ring.
b. Heat piston to 60 to 70°C (140 to 158°F) with industrial use drier or equivalent.
c. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 inch).
17. Remove main bearing cap bolt.
NOTE: Use TORX socket (size E14).
^ Before loosening main bearing cap bolts, measure crankshaft end play.
^ Loosen them in the numerical order shown in the figure in several different steps.
18. Remove main bearing beam.
19. Remove main bearing cap.
^ Using main bearing cap bolts, remove main bearing cap while shaking it back-and-forth.
20. Remove crankshaft.
21. Remove main bearings and thrust bearings from cylinder block and main bearing cap.
CAUTION: Identify installation positions, and store them without mixing them up.
22. Remove oil jet.
ASSEMBLY
1. Fully air-blow the engine coolant and engine oil passages in the cylinder block, the cylinder bore and the crankcase to remove any foreign material.
CAUTION: Use a goggles to protect your eye.
2. Install each plug to the cylinder block as shown.
^ Apply thread sealant to the thread of cylinder block drain plugs.
Use Genuine Thread Sealant or equivalent.
Cylinder block drain plug (Front side) "A": 9.8 Nm (1.0 Kg-m, 87 inch lbs.)
Cylinder block drain plug (RH) "B": 19.6 Nm (2.0 kg-m, 14 ft. lbs.)
Cylinder block drain plug (LH) "C": 19.6 Nm (2.0 kg-m, 14 ft. lbs.)
3. Install oil jet.
^ Insert oil jet dowel pin into the cylinder block dowel pin hole, and tighten the mounting bolts.
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
b. Install the thrust bearings to the both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.
^ Install the thrust bearings with the oil groove facing to the crankshaft arm (outside).
^ Install bearing with a projection on one end on cylinder block, and bearing with a projection at center on cap. Align each projection with mating notch.
c. Install the main bearings paying attention to the direction.
^ The main bearing with an oil hole and groove goes on the cylinder block. The one without them goes on the main bearing cap.
^ Before installing the bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
^ When installing, align the bearing stopper to the notch.
^ Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install the crankshaft to the cylinder block.
^ While turning the crankshaft by hand, make sure it turns smoothly.
6. Install main bearing cap.
^ Main bearing caps are identified by identification mark cast on them. For installation, face front mark to front side.
NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
7. Install main bearing beam.
^ Install main bearing beam with front mark facing downward (oil pan side).
^ Install main bearing beam with front mark facing front of engine.
8. Inspect outer diameter of main bearing cap bolt.
9. Install main bearing cap bolt.
a. Apply new engine oil to threads and seat surfaces of mounting bolts.
b. Tighten bolts in numerical order with tightening torque in several different steps.
35.3 Nm (3.6 kg-m, 26 ft. lbs.)
c. Turn all bolts another "90" degrees clockwise (Angle tightening).
CAUTION: Use an angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection.
^ After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
^ Check crankshaft end play.
10. Inspect outer diameter of connecting rod bolt.
11. Install the piston to the connecting rod.
a. Using a snap ring pliers, install a new snap ring to the groove of the piston rear side.
^ Insert it fully into groove to install.
b. Install the piston to the connecting rod.
^ Using an industrial drier or similar tool, heat the piston until the piston pin can be pushed in by hand without excess force [approximately 60 to 70 °C (140 to 158°F)]. From the front to the rear, insert the piston pin into the piston and then connecting rod.
^ Assemble so that the front mark on the piston crown and the cylinder number on the connecting rod are positioned as shown in the figure.
c. Install a new snap ring to the groove of the piston front side.
^ Insert it fully into groove to install.
^ After installing, make sure the connecting rod moves smoothly.
12. Using a piston ring expander (commercial service tool), install the piston rings.
^ If there is stamped mark on ring, mount it with marked side up.
NOTE: If there is no stamp on ring, no specific orientation is required for installation.
Stamped mark:
Top ring:-
Second ring: "R"
CAUTION: Be careful not to damage the piston.
^ Position each ring with the gap as shown in the figure referring to the piston front mark.
13. Install the connecting rod bearings to the connecting rod and the connecting rod cap.
^ When installing the connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
^ When installing, align the connecting rod bearing stopper protrusion with the cutout of the connecting rod to install.
^ Check the oil hole on the connecting rod and that on the corresponding bearing are aligned.
14. Install the piston and connecting rod assembly to the crankshaft.
^ Position the crankshaft pin corresponding to the connecting rod to be installed onto the bottom dead center.
^ Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
^ Match the cylinder position with the cylinder number on the connecting rod to install.
^ Using a piston ring compressor (SST) or suitable tool, install the piston with the front mark on the piston crown facing the front of the engine.
CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
15. Install the connecting rod cap.
^ Match the stamped cylinder number marks on the connecting rod with those on the cap to install.
^ Be sure that front mark on connecting rod cap is facing front of engine.
16. Tighten the connecting rod bolt as follows.
a. Apply engine oil to the threads and seats of the connecting rod bolts.
b. Tighten bolts.
19.6 Nm (2.0 kg-m, 14 ft. lbs.)
c. Then tighten all bolts "90" degrees clockwise (Angle tightening).
CAUTION: Always use an angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone.
^ After tightening the bolt, make sure that the crankshaft rotates smoothly.
^ Check the connecting rod side clearance.
17. Install baffle plate to main bearing beam.
18. Install rear oil seal retainer to cylinder block.
^ Apply liquid gasket to rear oil seal retainer using tube presser [SST: WS39930000 (-)] as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
CAUTION: Replace with the new parts.
NOTE: Rear oil seal with rear oil seal retainer.
19. Install pilot converter using suitable tool.
^ Outer diameter of drift
Pilot bushing: Approximately 17 mm (0.67 inch)
Pilot converter: Approximately 33 mm (1.30 inch)
^ Press-fit pilot bushing or pilot converter with its chamfer facing crankshaft.
20. Install drive plate.
^ Install drive plate and reinforcement plate as shown in figure.
^ Secure the crankshaft using a ring gear stopper [SST: KV1011770 (344716)].
^ Tighten the installation bolts crosswise over several times.
21. Install knock sensor.
^ Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
^ Install knock sensor so that connector faces to front of engine.
^ Do not tighten the mounting bolts while holding the connector.
^ Make sure that the knock sensor does not interfere with other parts.
CAUTION: If any impact by dropping is applied to the knock sensor, replace it with new one.
^ After installing knock sensor, connect sub-harness, and lay it out to rear of engine.
22. Install followings in reverse order of removal.