Disassembly and Assembly
CYLINDER BLOCK
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Disassembly and Assembly
DISASSEMBLY
NOTE: Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, note with difference in steps and etc.
1. Remove engine assembly from vehicle, and separate front suspension member, transmission and front final drive from engine.
2. Remove the parts that may restrict installation of engine to widely use engine stand.
NOTE: The procedure is described assuming that you use widely use engine holding the surface, to which transmission is installed.
a. Remove drive plate.
^ Holding ring gear with ring gear stopper (SST).
^ Loosen mounting bolts diagonally order.
CAUTION:
^ Do not disassemble drive plate.
^ Do not place 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.
b. Remove engine rear plate.
3. Lift engine with hoist to install it onto widely use engine stand.
CAUTION: Use engine stand that has a load capacity [approximately 240 kg (529 lb) or more] large enough for supporting the engine weight.
^ If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand.
- Intake manifolds (upper and lower).
- Exhaust manifold.
- Fuel tube and fuel injector assembly.
- A/C compressor; Refer to ATC-139, Components. [1][2]Exploded Views
- Ignition coil.
- Rocker cover.
- Other removable brackets
NOTE: The figure shows an example of widely use engine stand that can hold mating surface of transmission with drive plate and rear plate removed.
CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
4. Drain engine oil.
5. Drain engine coolant from inside engine by removing water drain plugs B as shown in the figure.
6. Remove the following parts and related parts (The parts listed in step 3 are not included here.)
^ Oil pan and oil strainer.
^ Crankshaft pulley, front cover and timing chain.
^ Camshaft.
^ Cylinder head.
7. Remove knock sensor.
CAUTION: Carefully handle sensor, avoiding shocks.
8. Remove piston and connecting rod assembly as follows:
^ Before removing piston and connecting rod assembly, check the connecting rod side clearance.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.
CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
9. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION: Identify installation positions, and store them without mixing them up.
10. Remove piston rings from piston.
^ Before removing the piston rings, check the piston ring side clearance.
^ Use piston ring expander (commercial service tool).
CAUTION:
^ When removing piston rings, be careful not to damage piston.
^ Be careful not to damage piston rings by expanding them excessively.
11. Remove piston from connecting rod as follows:
a. Using snap ring pliers, remove the snap rings.
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 (0.8 inch).
12. Remove rear oil seal retainer from cylinder block.
^ Insert screwdriver or similar tool between rear end of crankshaft counter weight and rear oil seal retainer, and separate liquid gasket to remove.
CAUTION: Be careful not to damage the mating surfaces.
13. Using screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
14. Remove main bearing cap as follows:
^ before loosening main bearing cap bolts, measure the crankshaft end play.
^ Loosen main bearing cap bolts in several different steps.
a. Remove cover attached to the rear left side of cylinder block (next to the starter motor housing).
NOTE: Bolts (No. 27 shown in the figure) are installed on the inside of cover.
b. Loosen side bolts (M10) starting from 30 to 21 to remove.
c. Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to remove.
d. Loosen main bearing cap bolts (M12) starting from 10 to 1 to remove.
e. Using main bearing cap remover (SST), remove main bearing cap.
15. Remove crankshaft.
16. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION: Identify installation positions, and store them without mixing them up.
17. If pilot converter must be removed, remove it from the rear end of the crankshaft using pilot bushing puller (SST).
^ It is possible to remove pilot converter without hoisting engine with engine stand.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
CAUTION: Use goggles to protect your eye.
2. Install each plug to the cylinder block. (Only screwed-type plugs are shown in the figure.)
^ Apply sealant to the thread of each plug A and D.
^ Use Genuine High Strength Locking Sealant or equivalent.
^ Apply sealant to the thread of each plug B and C.
^ Use Anaerobic Liquid Gasket or equivalent.
^ Replace copper washers with new ones.
^ Tighten each plug as specified below.
3. Install main bearings and thrust bearings as follows:
a. Remove dust, dirt and oil on the bearing mating surfaces of cylinder block and main bearing caps.
b. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block and main bearing cap
^ Install thrust bearings with the oil groove facing the crankshaft arm (outside).
^ Install thrust bearing with a protrusion on one end on cylinder block, and thrust bearing with a protrusion at center on main bearing cap. Align each protrusion with mating notch.
c. Install main bearings paying attention to the direction.
^ Main bearing with oil hole and groove goes on cylinder block. The one without them goes on main bearing cap.
^ Before installing main 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 main bearing stopper protrusion to cutout of cylinder block and main bearing caps.
^ Ensure the oil holes on cylinder block and those on the corresponding bearing realigned.
4. Install pilot converter to crankshaft, if removed.
^ With drift [outer diameter: approximately 35 mm (1.38 inch)], press-fit as far as it will go.
^ Press-fit pilot converter with its chamfering side facing crankshaft as shown in the figure.
^ It is possible to remove pilot converter without hoisting engine with engine stand.
5. Install crankshaft to cylinder block.
^ While turning crankshaft by hand, make sure it turns smoothly.
6. Install main bearing caps.
^ Align the identification number to the journal position to install.
^ Install the upper side of the identification number facing the front of engine. (The number shall be read correctly from the rear of engine.)
^ Using plastic hammer or similar tool, tap them lightly to seat them on the installation position.
NOTE: Main bearing cap cannot be replaced as a single parts, because it is machined together with cylinder block.
7. Install each main bearing cap bolt as follows:
a. Apply new engine oil to threads and seating surface of main bearing cap bolts, and tighten all bolts temporarily.
b. Tighten main bearing cap bolt (M12) in order of 1 to 10.
Torque: 39.2 Nm (4.0 kg-m, 29 ft. lbs.)
c. Tighten main bearing cap sub bolt (M9) in order of 11 to 20.
Torque: 29.4 Nm (3.0 kg-m, 22 ft. lbs.)
d. Tighten main bearing cap bolt (M12) to 40° clockwise in order of 1 to 10. (Angle tightening)
CAUTION: Use angle wrench (SST) to check tightening angle in step d and e. Do not make judgment by visual inspection.
e. Tighten main bearing cap sub bolt (M9) to 30° clockwise in order of 11 to 20. (Angle tightening)
f. Tighten side bolt (M10) in order of 21 to 30.
Torque: 49 Nm (5.0 kg-m, 36 ft. lbs.)
^ After installing main bearing cap bolts, make sure that crankshaft can be rotated smoothly.
^ Check the crankshaft end play.
g. Install cover of cylinder block rear left side (next to the starter motor housing).
8. Install new rear oil seal on rear oil seal retainer.
^ Install new rear oil seal so that each seal lip is oriented as shown in the figure.
^ Install rear oil seal to rear oil seal retainer with rear oil seal drift (commercial service tool).
Rear oil seal drift
Outer diameter 102 mm (4.02 inch)
Inner diameter: 86 mm (3.39 inch)
^ Tap until flattened with front edge of rear oil seal retainer. Do not damage or scratch outer circumference of oil seal.
^ Make sure the garter spring is in position and seal lips not inverted.
9. Install rear oil seal retainer.
^ Apply new engine oil to both oil seal lip and dust seal lip. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - ) to rear oil seal retainer as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
10. Install piston to connecting rod.
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
^ Insert it fully into groove to install.
b. Install piston to connecting rod.
^ Using industrial use drier or similar tool, heat piston until 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 piston pin into piston and connecting rod.
^ Assemble so that the front mark on the piston head and the oil holes and the cylinder No. on connecting rod are positioned as shown in the figure.
c. Using snap ring pliers, install new snap rings to the groove of the piston front side.
^ Insert it fully into groove to install.
^ After installing, make sure that connecting rod moves smoothly
11. Using piston ring expander (commercial service tool), install piston rings.
CAUTION:
^ When installing piston rings, be careful not to damage piston.
^ Be careful not to damage piston rings by expending them excessively.
^ Position each ring with the gap as shown in the figure, referring to the piston front mark.
^ Install top ring and second ring with the stamped surface facing upward.
Stamped mark
Top ring: R
Second ring: 2R
12. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
^ Before installing 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 connecting rod and connecting rod bearing cap to install.
^ Ensure the oil holes on connecting rod and that on the corresponding bearing realigned.
13. Install piston and connecting rod assembly to crankshaft.
^ Position the crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
^ Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
^ Match the cylinder position with the cylinder No. on connecting rod to install.
^ Be sure that front mark on piston head is facing front of engine.
^ Using piston ring compressor [SST: EM03470000 (J8037)], install piston with the front mark on the piston head facing the front of engine.
CAUTION: Be careful not to damage cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
14. Install connecting rod bearing cap. Match the stamped cylinder number marks on connecting rod with those on cap to install.
15. Tighten connecting rod nuts as follows:
a. Apply new engine oil to the threads and seats of connecting rod bolts and nuts.
b. Tighten connecting rod nuts.:
Torque: 14.7 Nm (1.5 kg-m, 11 ft. lbs.)
c. Then tighten all connecting rod nuts 60° clockwise. (Angle tightening)
CAUTION: Use angle wrench (SST) to check tightening angle. Do not make judgment by visual inspection.
^ After tightening connecting rod nuts, make sure that crankshaft rotates smoothly.
^ Check the connecting rod side clearance.
16. Install knock sensor.
^ Install it with its connector facing the rear of engine.
^ Install the sub-harness with its shorter branch line to the right bank.
CAUTION:
^ Do not tighten mounting bolts while holding connector.
^ If any impact by dropping is applied to knock sensor, replace it with new one.
NOTE:
^ Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
^ Make sure that knock sensor does not interfere with other parts.
17. Note the following, and assemble in the reverse order of disassembly after this step.
Drive plate
^ When installing drive plate to crankshaft, be sure to correctly align crankshaft side guide pin and drive plate side guide pin hole.
^ If these are not aligned correctly, engine runs roughly and MIL turns on.
^ Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown in the figure.
^ Face chamfered or rounded edge side to crankshaft.
^ Holding ring gear with ring gear stopper [SST: J-45476].
^ Tighten mounting bolts crosswise over several times.
^ When install pilot converter, using drift [outer diameter: approximately 35 mm (1.38 inch)]. Press-fit as far as it will go.
CAUTION: Make sure that guide pin is installed at the rear end of crankshaft.