Disassembly and Assembly
CYLINDER BLOCK
Disassembly and Assembly
CAUTION:
^ Apply new engine oil to parts as marked in illustrations before installation.
^ Place removed parts such as bearings and bearing caps in their proper order and direction.
^ When installing the connecting rod nuts, and main bearing cap bolts, apply new engine oil to the threads and mating surfaces
^ Do not allow any magnetic materials to contact the signal plate teeth on the drive plate.
DISASSEMBLY
1. Remove the engine assembly. Refer to "ENGINE ASSEMBLY".
2. Install Tools to the right side of cylinder block.
Tool numbers : KV10117001(-) : KV10106500 ( - )
Use the spacer on the engine rear side.
3. Lift engine and mount it on Tool.
Tool numbers : KV10117001 ( - ) : KV10106500 ( - ) : ST0501S000 ( - )
^ A commercial engine stand can be used.
CAUTION: Use an engine stand that has a load capacity of approximately 220 kg (441 lbs.) or more.
NOTE: This example is an engine stand for holding at the transaxle mounting side with the drive plate removed.
4. Remove the knock sensor.
CAUTION: Carefully handle sensor avoiding shocking it.
5. Drain the engine of all coolant and oil.
6. Remove the lower and upper oil pans. Refer to "REMOVAL".
7. Remove the timing chain. Refer to "REMOVAL".
8. Remove oil pump. Refer to "REMOVAL".
9. Remove the cylinder heads. Refer to "REMOVAL".
10. Lock crankshaft using Tool, and remove drive plate (A/T) or flywheel bolts.
^ Loosen the bolts in diagonal order.
Tool number : KV10117700 (J44716)
CAUTION:
^ Do not disassemble drive plate.
^ Never place the 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.
11. Remove pilot bushing (M/T) or pilot converter (A/T) using Tool.
Tool number ST16610001 (J23907)
12. Cut away liquid gasket using Tool and remove rear oil seal retainer. Refer to "REMOVAL OF LIQUID GASKET SEALING".
Tool number KV10111100 (J37228)
CAUTION:
^ Be careful not to damage mounting surface.
^ If rear oil seal retainer is removed, replace it with a new one.
NOTE: Rear oil seal and retainer form a single part and are handled as an assembly.
13. Remove baffle plate from main bearing beam.
14. Remove the piston and connecting rod assemblies.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and connecting rod assembly out to the cylinder head side.
^ Before removing the piston and connecting rod assembly, check the connecting rod side clearance. Refer to "CONNECTING ROD".
15. Remove the connecting rod bearings.
CAUTION:
^ When removing the connecting rod side bearings, note the installation position. Keep them in the correct order.
16. Remove the piston rings from the piston.
^ Use a piston ring expander.
^ Before removing the piston rings, check the piston ring side clearance. Refer to "PISTON RING SIDE CLEARANCE".
CAUTION:
^ When removing the piston rings, be careful not to damage the piston. Do not expand the rings excessively.
^ Be careful to mark the rings if they are to be reused so they are installed in their original position.
17. Remove the piston from the connecting rod as follows.
a. Using a snap ring pliers, remove the snap ring.
b. Heat the pistons to 60° - 70°C (140° - 158°F).
c. Push out the piston pin with a suitable tool, with an outer diameter approximately 20 mm (0.8 inch).
18. Loosen the main bearing cap bolts in the order shown and remove the main bearing beam, bearing caps and crankshaft.
^ Before loosening the main bearing cap bolts, measure the crankshaft side clearance. Refer to "OUT-OF-ROUND AND TAPER OF CRANKSHAFT".
19. Remove the oil jets.
20. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.
CAUTION: When removing them, note their direction and position. Keep them in the correct order for installation.
ASSEMBLY
1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials.
WARNING: Use goggles to protect your eyes.
2. Apply liquid gasket and install each plug into the cylinder block.
^ Use Genuine Silicone RTV Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
3. Install the oil jets.
^ Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the oil jet bolts.
Oil jet bolts : 23.6 - 30.4 Nm (2.4 - 3.1 kg-m, 18 - 22 ft. lbs.)
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
b. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.
^ Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
^ Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.
5. Set the upper main bearings in their proper positions on the cylinder block.
^ Confirm the correct main bearings are used. Refer to "PISTON-TO-CYLINDER BORE CLEARANCE".
6. Check specifications for the re-use of the main bearing cap bolts.
^ Measure d1 and d2 as shown.
^ For d2, select the minimum diameter in the measuring area.
^ If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.
Limit (d1 - d2) : 0.11 mm (0.0043 inch)
7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts.
a. Make sure that the front marks on the main bearing beam faces the front of the engine.
b. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
c. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
d. Lubricate the threads and seat surfaces of the bolts with new engine oil.
e. Tighten the bearing cap bolts in two steps in the order shown:
Bearing cap bolts
Step 1 : 32 - 38 Nm (3.3 - 3.9 kg-m, 24 - 28 ft. lbs.)
Step 2 : 90° - 95° degrees clockwise
CAUTION: Measure the tighten angle with an angle wrench. Do not measure visually.
8. Using a dial indicator, measure the clearance between the thrust bearings and the connecting rods when the crankshaft is moved from front to rear.
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit :0.30 mm (0.0118 inch)
^ If beyond the limit, replace the thrust bearings and measure again. If still beyond the limit, replace the crankshaft.
9. Install the rear oil seal retainer.
^ Apply sealant to rear oil seal retainer using Tool as shown.
Tool number : WS39930000 ( - )
^ Use Genuine Silicone RTV Sealant, or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
Rear oil seal retainer bolts : 8.2 - 9.3 Nm (0.83 - 0.95 kg-m, 72 - 82 inch lbs.)
CAUTION: Rear oil seal is replaced with the rear oil seal retainer and must be replaced as an assembly.
10. Install the piston to the connecting rod.
a. Using suitable snap ring pliers, install the snap ring into the pin groove of the piston rear side.
^ Insert it fully into groove to install.
b. Install the piston to the connecting rod.
^ Heat the piston until the piston pin can be pushed in by hand without excess force [approximately 60° - 70°C (140° to 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.
^ Assemble so that the front mark on the piston crown and the oil holes and the cylinder No. on the connecting rod are positioned as shown.
c. Install the snap ring into the front of the piston pin-groove.
^ After installing, check that the connecting rod pivots smoothly on the pin.
11. Install the piston rings using a piston ring expander.
^ Install the top ring and the second ring with the stamped surface facing upward. If the ring is not stamped it can face in either direction.
CAUTION:
^ Be careful not to damage the piston.
^ When the piston rings are not replaced, remount the rings in their original positions.
^ When replacing the piston rings, those without punch marks can be mounted either side up.
^ Position each ring with the gap as shown, referring to the piston front mark.
12. Install the connecting rod bearings to the connecting rod and the connecting rod cap.
^ When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it.
^ When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install.
^ Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.
13. Install the piston and connecting rod assembly into the corresponding cylinder.
^ Position the crankshaft pin corresponding to the connecting rod to be installed onto the bottom dead center.
^ Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
^ Match the cylinder position with the cylinder No. on the connecting rod to install.
^ Install the piston using Tool with the front mark on the piston crown facing the front of the engine.
Tool number : EM03470000 (J8037)
CAUTION: Be careful not to damage the crankshaft pin and cylinder wall, resulting from an interference of the connecting rod big end.
14. Install the connecting rod cap.
^ Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
^ Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine.
^ Lubricate the threads and seat surfaces with new engine oil.
15. Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand.
^ Measure the outer diameter of the connecting rod cap bolt as shown.
Outer diameter "d" of the connecting rod bolt
Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit : 7.75 mm (0.3051 inch)
16. Tighten the connecting rod nuts in two steps:
Step 1 : 19 - 21 Nm (1.9 - 2.1 kg-m, 14 - 15 ft. lbs.)
Step 2 : 90° - 95° degrees clockwise
CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.
^ Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
^ After tightening the nuts, make sure that the crankshaft rotates smoothly.
^ Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft.
Connecting rod side clearance:
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit : 0.40 mm (0.0157 inch)
17. Install the baffle plate.
Baffle plate bolts : 8.14 - 9.51 Nm (0.83 - 0.97 kg-m, 72 - 84 inch lbs.)
18. Install the knock sensor.
Knock sensor bolt : 16 - 26 Nm (1.6 - 2.7 kg-m, 12 - 20 inch lbs.)
^ Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
^ Install the knock sensor with the connector facing the rear of the engine.
^ Do not tighten the knock sensor bolt while holding the connector.
^ Make sure that the knock sensor does not interfere with other parts.
CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
19. Install the pilot bushing (M/T) or pilot converter (A/T) using suitable tool.
Outer diameter of drift
Pilot bushing : Approx.17 mm (0.67 inch)
Pilot converter : Approx. 33 mm (1.30 inch)
^ Install pilot bushing or pilot converter as shown.
20. Install the flywheel (M/T), if equipped.
^ When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.
Flywheel bolts : 83 - 93 Nm (8.5 - 95 kg-m, 61 - 69 ft. lbs.)
21. Install the drive plate (A/T), if equipped.
^ Install the drive plate and reinforce plate in the direction shown.
^ Align dowel pins of crankshaft rear and drive plate with pin holes of each part.
^ Secure the crankshaft using Tool.
Tool number : KV10117700 (J44716)
^ Tighten the drive plate bolts in one or two steps.
Drive plate bolts : 83 - 93 Nm (8.5 - 95 kg-m, 61 - 69 ft. lbs.)
22. Install the cylinder head. Refer to "Removal and Installation".
23. Install the oil pump. Refer to "INSTALLATION".
24. Install the timing chain. Refer to "INSTALLATION".
25. Install the upper and lower oil pans. Refer to "INSTALLATION".
26. Remove the engine from the stand and install the engine assembly into the vehicle. Refer to "Removal and Installation".
27. Assembly of the remaining parts is in the reverse order of disassembly.
28. Fill the engine with the specified oil and coolant. Refer to "Fluids and Lubricants".
CAUTION: Wait at least 30 minutes for the sealant to set-up before filling the engine with fluids and running it.