Disassembly and Assembly

Part 1:

Part 2:

CYLINDER BLOCK

Disassembly and Assembly
DISASSEMBLY
1. Remove engine assembly from vehicle, and separate front suspension member and transmission from engine. Refer to "ENGINE ASSEMBLY".
2. Remove engine mounting brackets (RH and LH). Refer to "ENGINE ASSEMBLY".
3. Remove exhaust manifold (right bank). Refer to "EXHAUST MANIFOLD AND THREE WAY CATALYST".





4. Install engine sub-attachment with engine stand shaft [SST] to right side of cylinder block.
^ Use spacer to engine rear side.





5. Lift engine, and mount it onto engine stand [SST].





^ A widely use engine stand can be used.

CAUTION: Use engine stand that has a load capacity [approximately 220 kgf (441 lbs.) or more] large enough for supporting the engine weight.

NOTE: This example is engine stand for holding at transmission mounting side with flywheel (M/T models) or drive plate (A/T models) removed.

6. Drain engine oil. Refer to "Changing Engine Oil".





7. Drain engine coolant by removing water drain plugs from cylinder block both sides at "B" and "C" and cylinder block front side at "A" as shown in the figure.
8. Remove clutch cover and clutch disc (M/T models). Refer to "CLUTCH DISC CLUTCH COVER".





9. Remove flywheel (M/T models) or drive plate (A/T models). Fix crankshaft with ring gear stopper [SST], and remove mounting bolts.
^ Loosen mounting bolts in diagonal order.
^ Use TORX socket for flywheel mounting bolts (size: T55, commercial service tool)





CAUTION:
^ Do not disassemble flywheel (M/T models) and drive plate (A/T models).
^ Do not place drive plate (A/T models) 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 cylinder head.
11. Remove knock sensor.

CAUTION: Carefully handle sensor avoiding shocks.





12. Remove pilot bushing (M/T models) or pilot converter (A/T models) using pilot bushing puller [SST] or suitable tool as necessary.
13. Remove rear oil seal retainer.
^ Remove by inserting screwdriver between main bearing cap and rear oil seal retainer.

CAUTION: If rear oil seal retainer is removed, replace it with new one.

NOTE: Regard both rear oil seal and retainer as an assembly.

14. Remove baffle plate from main bearing beam.
15. Remove piston and connecting rod assembly as follows:
^ Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to "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.

16. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.

CAUTION: Identify installation position, and store them without mixing them up.





17. Remove piston rings form piston.
^ Before removing piston rings, check the piston ring side clearance. Refer to "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.

18. Remove piston from connecting rod as follows:





a. Using snap ring pliers, remove 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).
19. Remove main bearing cap bolts.

NOTE: Use TORX socket (size E14).

^ Before loosening main bearing cap bolts, measure the crankshaft end play. Refer to "CRANKSHAFT END PLAY."





^ Loosen main bearing cap bolts in reverse order shown in the figure in several different steps.





20. Remove main bearing beam.





21. Remove main bearing caps.
^ Using main bearing cap bolts, remove main bearing cap while shaking it back-and-forth.
22. Remove crankshaft.
23. Remove main bearings and thrust bearings from cylinder block and main bearing caps.

CAUTION: Identify installation positions, and store them without mixing them up.

24. Remove oil jet.

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 a goggles to protect your eye.





2. Install each plug to cylinder block as shown in the figure.
^ Apply sealant to the thread of water drain plugs "A", "B" and "C".

Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
^ Apply sealant to the thread of plugs "D" and "E". Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
^ Apply sealant to the thread of plug "F". Use Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
^ Replace washers with new one.





^ Tighten each plug as specified.





3. Install oil jet.
^ Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten mounting bolts.
4. Install main bearings and thrust bearings as follows:
a. Remove dust, dirt, and engine oil on 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 crankshaft arm (outside).
^ Install thrust bearing with a protrusion on one end on cylinder block, and thrust bearing with a protrusion at center on 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 are aligned.
5. Install crankshaft to cylinder block.
^ While turning crankshaft by hand, check that 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 Dan side).





^ Install main bearing beam with front mark facing front of engine.
8. Inspect the outer diameter of main bearing cap bolt. Refer to "MAIN BEARING CAP BOLT OUTER DIAMETER"
9. Install main bearing cap bolts in numerical order as shown in the figure as follows:





a. Apply new engine oil to threads and seat surfaces of main bearing cap bolts.
b. Tighten main bearing cap bolts in several different steps.
Tightening Torque: 32.3 - 38.3 Nm (3.3 - 3.9 kg-m, 24 - 28 ft. lbs.)





c. Turn all bolts another 90 to 95 degrees clockwise [Target: 90 degrees (Angle tightening)].

CAUTION: Use angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection.

^ After installing main bearing cap bolts, make sure that crankshaft can be rotated smoothly by hand.
^ Check the crankshaft end play. Refer to "CRANKSHAFT END PLAY".
10. Inspect the outer diameter of connecting rod bolt. Refer to "CONNECTING ROD BOLT OUTER DIAMETER".
11. Install piston to connecting rod as follows:
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 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 cylinder number on connecting rod are positioned as shown in the figure.
c. Install new snap ring to the groove of the piston front side.
^ Insert it fully into groove to install.
^ After installing, make sure that connecting rod moves smoothly.





12. 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.





^ 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





^ Position each ring with the gap as shown in the figure referring to the piston front mark.
^ Check the piston ring side clearance. Refer to "PISTON RING SIDE CLEARANCE".

13. 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 connecting rod bearing stopper protrusion with cutout of connecting rods and connecting rod bearing caps to install.
^ Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
14. 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 head is facing front of engine.





^ Using piston ring compressor [SST] or suitable tool, install piston with the front mark on the piston head facing the front of 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 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 on connecting rod bearing cap is facing front of engine.
16. Tighten connecting rod bolts as follows:
a. Apply engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts.
Tightening Torque: 18.6 - 20.6 Nm (1.9 - 2.1 kg-m, 14 - 15 ft. lbs.)





c. Then tighten all bolts 90 to 95 degrees clockwise [target: 90 degrees (Angle tightening)].

CAUTION: Use angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection.

^ After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
^ Check the connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE".

17. Install baffle plate to main bearing beam.
18. Install new rear oil seal retainer to cylinder block.
^ 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. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

CAUTION: Replace with a new parts.

NOTE: Regard both rear oil seal and retainer as an assembly.





19. Install pilot bushing (M/T models) or pilot converter (A/T models).
^ With drift of the following outer diameter, press-fit as far as it will go.
Pilot bushing: approximately 17 mm (0.67 inch)
Pilot converter: approximately 33 mm (1.30 inch)





^ Press-fit pilot bushing as the dimension in the figure. (M/T models)





^ Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)





20. Install knock sensor.
^ Install knock sensor so that connector faces front of engine.
^ After installing knock sensor, connect harness connector, and lay it out to rear of engine.

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.

21. Note the following, assemble in the reverse order of disassembly after this step.
Flywheel (M/T models)





^ When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.





^ There is a mating mark on the clutch cover side of flywheel. Refer it during installation.





^ Holding ring gear with ring gear stopper [SST], tighten securing bolts with TORX socket (size: T55, commercial service tool).
^ Tighten the mounting bolts crosswise over several times.

Drive plate (A/T models)





^ Install drive plate and reinforcement plate as shown in the figure.
^ Holding ring gear with ring gear stopper [SST: KV10117700 (J44716)].
^ Tighten the mounting bolts crosswise over several times.