Removal

Disassembly

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.
- 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 for this procedure.

1. Remove the engine assembly from the vehicle.
2. Install the engine to engine stand for disassembly.
3. Remove the intake manifold and exhaust manifold.
4. Remove the timing chain.
5. Remove the water temperature control assembly.
6. Remove the cylinder head.
7. Remove the oil pump.
8. Remove the oil filter assembly.
9. Remove the drive plate (A) and adapter plate (B).




10. Remove the crankshaft adapter (A).




11. Remove the knock sensor (A).








12. Remove the upper oil pan (A).




13. Remove the baffle plate (A).




14. Remove the rear oil seal case (A).




15. Remove the oil drain cover (A).




16. Check the connecting rod end play.
17. Check the connecting rod cap oil clearance.
18. 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 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.

19. Remove the crankshaft main bearing cap and check oil clearance.
20. Check the crankshaft end play.
21. 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.

22. 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.
23. 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.

24. Disconnect connecting rod from piston.Using a press, remove the piston pin from the piston.

Press-in load :800 - 1400kg (1764 - 3086lb)