Disassembly
CYLINDER BLOCK - 2.5L (QR25DE):
CAUTION: Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove the engine and transaxle as an assembly from the vehicle and separate the transaxle from the engine.
2. Mount the engine on a suitable engine stand.
3. Drain any remaining engine oil and coolant from the engine.
4. Remove the following components and associated parts.
- Exhaust manifold and three way catalyst assembly.
- Intake manifold collector.
- Intake manifold and fuel tube assembly.
- Ignition coils.
- Rocker cover.
- Front cover, timing chain, and balancer unit.
- Cylinder head.
5. Remove the cylinder block heater, if equipped.
6. Remove the knock sensor.
CAUTION: Carefully handle the sensor and do not drop the sensor.
7. Remove crankshaft position sensor (POS).
CAUTION: Avoid impacts such as a dropping. Do not disassemble. Keep it away from metal particles.
Do not place sensor close to magnetic materials.
8. Remove the flywheel (M/T models) or drive plate (A/T models). Hold the crankshaft with a stopper plate and remove the mounting bolts using Tool.
CAUTION: Be careful not to damage the flywheel contact surface for the clutch disc.
NOTE: The flywheel two-block construction allows movement in response to transmission side pressure, or when twisted in its rotational direction, therefore, some amount of noise is normal.
9. Remove pilot converter using Tool (A/T models).
10. Remove the piston and connecting rod assemblies.
a. Position the crankshaft and corresponding connecting rod, to be removed, to the bottom dead center stroke.
b. Remove the connecting rod cap. Number the cap so it can be assembled in the same position.
c. Using a hammer handle or similar tool, push the piston and connecting rod assembly out of the top of the cylinder block. Number the piston and rod so it can be assembled in the same position.
Before removing the piston and connecting rod assembly, check the connecting rod side clearance.
11. Remove the connecting rod bearings. If reusing, number them so they can be assembled in the same position and direction.
CAUTION: When removing them, note the installation position. Keep them in the correct order.
12. Remove the piston rings from the piston.
Use a piston ring expander.
CAUTION: When removing the piston rings, be careful not to damage the piston.
Be careful not to damage piston rings by expanding them excessively, if reusing them.
Before removing the piston rings, check the piston ring side clearance.
13. Remove the piston from the connecting rod as follows.
a. Using a snap ring pliers, remove the two snap rings.
b. Heat the piston to 60° - 70°C (140° - 158°F) with a heat gun, or equivalent.
c. Push out piston pin with a punch of an outer diameter of approximately 19 mm (0.75 inch).
14. Remove the lower cylinder block mounting bolts.
- Before loosening the lower cylinder block mounting bolts, measure the crankshaft side clearance.
- Loosen them in the order shown to remove them.
15. Remove the lower cylinder block.
Using Tool (seal cutter) cut the Silicone RTV Sealant and remove the lower cylinder block from the cylinder block.
CAUTION: Be careful not to damage the mounting surface.
16. Remove the crankshaft.
CAUTION: Do not damage or deform the signal plate while mounted on the crankshaft.
When setting the crankshaft on a flat surface, use a block of wood to avoid interference between the signal plate and the surface.
Do not remove signal plate unless it is necessary.
17. Pull the rear oil seal out of the rear end of the crankshaft.
CAUTION: Do not to damage the crankshaft or cylinder block when removing the rear oil seal.
NOTE: When replacing the rear oil seal without removing the cylinder block, use a screwdriver to pull it out from between crankshaft and block.
18. Remove the main bearings and thrust bearings from the cylinder block and lower cylinder block.
CAUTION: Identify and number the bearings, if reusing them, so that they are assembled in the same position and direction.