Disassembly and Assembly
CYLINDER BLOCK
Disassembly and Assembly
DISASSEMBLY
1.Remove the following parts:
- Oil pans (lower and upper): Refer to "Exploded View" Exploded View and "Exploded View" Exploded View.
- Front cover and timing chain: Refer to "Exploded View" Exploded View.
- Cylinder head: Refer to "Exploded View" Exploded View.
2.Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
3.Remove oil filter (for VVEL ladder assembly) from cylinder block, if necessary. Refer to "Exploded View" Exploded View.
4.Remove piston and connecting rod assembly as per the following:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
"Inspection" Inspection.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a.Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b.Loosen mounting bolts, and remove connecting rod bearing cap.
c.Using a hammer handle (A) 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.
5.Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
- Be careful not to drop connecting rod bearing, and to scratch the surface.
- Identify installation positions, and store them without mixing them up.
6.Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Refer to "Inspection" Inspection.
- Use a piston ring expander (commercial service tool) (A).
CAUTION:
- When removing piston rings, be careful not to damage piston.
- Be careful not to damage piston rings by expanding them excessively.
7.Remove piston from connecting rod as per the following:
a.Using snap ring pliers (A), remove snap rings.
b.Heat piston to 60 to 70�C (140 to 158�F) with an industrial use dryer (A) or an equivalent.
c.Push out piston pin using a stick that has an outer diameter of approximately 20 mm (0.79 in).
8.Remove rear oil seal and rear oil seal retainer assembly 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.
9.Using screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
10.Remove main bearing cap as per the following:
- Before loosening cylinder block bolts, measure the crankshaft end play. Refer to "Inspection" Inspection.
a.Loosen side bolts starting from No. 30 to 21 to remove.
b.Loosen main bearing cap sub bolts starting from No. 20 to 11 to remove.
c.Loosen main bearing cap bolts starting from No. 10 to 1 to remove.
d.Remove the main bearing cap.
- Insert bolts (1) into bolt holes, and then remove main bearing cap (2) by lifting up and shaking forward and backward.
CAUTION:
Be careful not to damage the mounting surface.
11.Remove crankshaft.
12.Remove main bearings and thrust bearings from main bearing cap and cylinder block.
CAUTION:
- Be careful not to drop main bearing, and to scratch the surface.
- Identify installation positions, and store them without mixing them up.
13.Remove oil jet.
ASSEMBLY
CAUTION:
Do not reuse washers.
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 eyes.
2.Install each plug to cylinder block as shown in the figure.
- Tighten each plug as specified below.
- Replace washers (1), (5) with new ones.
CAUTION:
Do not reuse washers.
- Apply sealant to the thread of water drain plug (3).
Use Genuine RTV silicone sealant or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.
- Apply sealant to the thread of plug (4).
Use high strength thread locking sealant or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.
3.Install main bearings and thrust bearings as per the following:
CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
a.Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
b.Install thrust bearings (2) to both sides of the No. 3 journal housing on cylinder block (1).
- Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
c.Install main bearings paying attention to the direction.
- Main bearing with oil hole (B) and groove (C) 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.
- Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
4.Install crankshaft to cylinder block.
- While turning crankshaft by hand, check that it turns smoothly.
5.Install main bearing caps as per the following:
- Align the identification number to the journal position to install.
- Install it with the front mark (indicated by stamping) facing the front 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.
6.Install each main bearing cap bolts as per the following:
CAUTION:
If main bearing cap bolts and sub bolts are re-used, check their outer diameters before installation. Refer to "Inspection" Inspection.
a.Apply new engine oil to threads and seat surfaces of main bearing cap bolts and sub bolts.
b.Tighten all bolts in order of (No. 1 - 30) temporarily.
c.Tighten main bearing cap bolts (M12) in order of No. 1 - 10.
d.Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20.
e.Tighten main bearing cap bolts (M12) in order of No. 1 - 10
(clockwise).
CAUTION:
Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
f.Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20.
(clockwise)
g.Tighten side bolts (M10) in order of No. 21 - 30.
- After installing bolts, check that crankshaft can be rotated smoothly by hand.
- Check the crankshaft end play. Refer to "Cylinder Block" [1][2]Specifications.
7.Install rear oil seal retainer.
- Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to rear oil seal retainer as shown in the figure.
Use Genuine RTV silicone sealant or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.
8.Install rear oil seal on rear oil seal retainer.
- Apply new engine oil to both oil seal lip (A) and dust seal lip (B).
- Install it so that each seal lip is oriented as shown in the figure.
CAUTION:
Be careful not to scratch or make burrs on circumference of oil seal.
- Press in rear oil seal (1) to the position as shown in the figure.
- Using a suitable drift [outer diameter: 101 mm (3.98 in)].
- Check the garter spring is in position and seal lips are not inverted.
9.Install piston to connecting rod as per the following:
- Assemble so that the front mark (A) on the piston head and the cylinder number (D) on connecting rod are positioned as shown in the figure.
a.Using snap ring pliers, install new snap ring to the groove of piston rear side.
- Insert it fully into groove to install.
b.Install piston to connecting rod.
- Using an industrial use dryer 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.
c.Install new snap ring to the groove of the piston front side.
- Insert it fully into groove to install.
- After installing, check that connecting rod moves smoothly.
10.Using a piston ring expander (commercial service tool) (A), 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.
- If there is stamped mark on ring, mount it with marked side up.
- Position each ring with the gap as shown in the figure referring to the piston front mark (D).
- Check the piston ring side clearance. Refer to "Inspection" Inspection.
11.Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
- 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 connecting rod bearing stopper protrusion (B) with cutout (A) of connecting rods and connecting rod bearing caps to install.
- Ensure the oil hole (C) on connecting rod and that on the corresponding bearing are aligned.
12.Install piston and connecting rod assembly to crankshaft.
- Position 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 number on connecting rod to install.
- Be sure that front mark on piston crown is facing the front of the engine.
- Using a piston ring compressor [SST: EM03470000 (J-8037)]
(A) or suitable tool, install 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.
13.Install connecting rod bearing cap.
- Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
- Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.
14.Tighten connecting rod bolts as per the following:
a.Inspect the outer diameter of connecting rod bolt. Refer to "Inspection" Inspection.
b.Apply engine oil to the threads and seats of connecting rod bolts.
c.Tighten connecting rod bolts.
d.Completely loosen connecting rod bolts.
e.Tighten connecting rod bolts.
f.Tighten connecting rod bolts. (clockwise)
CAUTION:
Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Never make judgment by visual inspection.
- After tightening connecting rod bolts, check that crankshaft rotates smoothly.
- Check the connecting rod side clearance. Refer to "Inspection" Inspection.
15.Install knock sensors (1).
- Install knock sensors in the direction shown in the figure.
- After installing knock sensor, connect harness connector, and lay it out to front of the engine.
CAUTION:
- Never tighten mounting bolts while holding connector.
- If any impact by dropping is applied to knock sensor, replace it with new one.
NOTE:
- Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
- Check that knock sensor does not interfere with other parts.
16.Install oil filter (for VVEL ladder assembly).
17.Assemble in the reverse order of disassembly.