Disassembly and Assembly
Disassembly and Assembly
CAUTION: Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Mount the engine on a suitable engine stand.
2. Drain any remaining engine oil and coolant from the engine.
3. 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.
^ Water pump.
4. Remove the cylinder block heater, if equipped.
5. Remove the knock sensor.
CAUTION: Carefully handle the sensor and do not drop the sensor.
6. 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.
7. 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.
Tool numbers
For Flywheel bolt: J-45737
For Drive plate bolt: J-45816
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.
8. Remove pilot converter using Tool (A/T models).
9. 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. Refer to CONNECTING ROD SIDE CLEARANCE.
10. 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.
11. 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.
^ Be careful not to damage piston rings by expanding them excessively, if reusing them.
12. 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).
13. Remove the lower cylinder block bolts.
^ Before loosening the lower cylinder block bolts, measure the crankshaft side clearance. Refer to CRANKSHAFT SIDE CLEARANCE.
^ Loosen them in the order shown to remove them.
14. Remove the lower cylinder block.
^ Using Tool cut the Silicone RTV Sealant and remove the lower cylinder block from the cylinder block.
Tool number: KV10111100 (J-37228)
CAUTION: Be careful not to damage the mounting surface.
15. 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.
16. Pull the rear oil seal out of the rear end of the crankshaft using suitable tool.
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.
17. 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.
ASSEMBLY
1. Using compressed air, clean out the coolant and oil passages in the cylinder block, the cylinder bore and the crankcase to remove any foreign material.
CAUTION: Use approved safety glasses to protect your eyes.
2. Apply Silicone RTV Sealant to the drain plugs. Install the drain plugs on the cylinder block.
^ Use Genuine Silicone RTV Sealant, or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
^ Replace the copper washers with new ones.
3. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil from the bearing mating surfaces of the cylinder block and lower cylinder block.
b. Install the thrust bearings to both sides of the No. 3 main bearing journal on the cylinder block.
^ Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
c. Install the main bearings paying attention to their position and direction.
^ The main bearing with an oil hole and groove goes on the cylinder block. The one without them goes on the lower cylinder block.
^ Only the main bearing (on the cylinder block) for No. 3 journal has different specifications.
^ Before installing the bearings, apply engine oil to the bearing friction surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
^ When installing align the bearing stopper to the notch
^ Make sure that the oil holes on the cylinder block and those on the corresponding bearing are aligned.
4. Install the signal plate to the crankshaft.
a. Position the crankshaft and signal plate using a positioning dowel pin, and tighten the signal plate bolts to specification.
Signal plate bolts: 12 - 14 Nm (1.22 - 1.43 kg-m, 9 - 10 ft. lbs.)
b. Remove the dowel pin.
CAUTION: Be sure to remove dowel pin before installing the crank shaft.
NOTE: Dowel pins for the crankshaft and signal plate are supplied as a set for each.
5. Install the crankshaft onto the cylinder block.
^ While turning the crankshaft by hand, check that it turns smoothly.
6. Apply Silicone RTV Sealant to positions shown and install the lower cylinder block.
^ Use Genuine Silicone RTV Sealant, or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
NOTE: Cylinder block and lower cylinder block are machined together. Neither of them can be replaced separately.
CAUTION: After the Silicone RTV Sealant is applied, the lower cylinder block installation must be finished within 5 minutes.
7. Tighten lower cylinder block bolts in three steps in the order shown.
NOTE: Apply new engine oil to threads and seat surfaces of the mounting bolts.
Lower cylinder block bolts
Step 1 (bolts 11 - 22): 22.6 - 27.5 Nm (2.3 - 2.8 kg-m, 17 - 20 ft. lbs.)
Step 2 (bolts 1 - 10): 36.3 - 42.1 Nm (3.7 - 4.3 kg-m, 27 - 31 ft. lbs.)
Step 3 (bolts 1 - 10): 60° - 65° (target: 60°)
CAUTION: Use an angle wrench (special service tool) or protractor to check tightening angle. Do not tighten by visual inspection.
^ Wipe off completely any protruding Silicone RTV Sealant on the exterior of engine.
^ Check crankshaft side clearance. Refer to CRANKSHAFT SIDE CLEARANCE.
^ After installing the mounting bolts, make sure that the crankshaft can be rotated smoothly by hand.
8. Apply new engine oil to new oil seal and install it using a suitable tool.
^ Install new oil seal in the direction shown.
9. Install rear oil seal using a suitable drift.
CAUTION:
^ Do not touch grease applied onto oil seal lip.
^ Be careful not to damage crankshaft and/or cylinder block.
^ Press fit oil seal straight to avoid causing burrs or tilting.
10. Install the piston to the connecting rod. Assemble the components in their original positions.
a. Using a snap ring pliers, install the snap ring into the grooves of the piston's rear side.
^ Insert the piston pin snap ring fully into groove.
b. Install the piston to the connecting rod.
^ Using a heat gun, heat the piston [approximately 60° - 70°C (140° - 158°F)] until the piston pin can be pushed in by hand without excessive force. From the front to the rear, insert the piston pin into the piston and 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 in the figure.
c. Install the piston pin snap ring into the front of the piston.
^ Check that the connecting rod moves smoothly.
11. Using a piston ring expander, install the piston rings. Assemble the components in their original positions.
CAUTION: Be careful not to damage the piston.
^ Position each ring with the gap as shown in the figure, referencing the piston front mark as the starting point.
^ Install the top ring and the second ring with the stamped surface facing upward.
Stamped mark: A (top ring): 2A (second ring)
12. Install the connecting rod bearings to the connecting rod and the connecting rod cap. Assemble the components in their original positions.
^ When installing the connecting rod bearings, apply engine oil to the bearing friction surface (inside). Do not apply oil to the back surface, but thoroughly clean the back.
^ When installing, align the connecting rod bearing stopper protrusion with the notch of the connecting rod to install.
^ Check the oil holes on the connecting rod and those on the corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft. Assemble the components in their original positions.
^ Rotate the crankshaft so the pin corresponding to the connecting rod to be installed is at the bottom dead center position.
^ Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
^ Match the cylinder position number with the cylinder No. on the connecting rod for installation.
^ Install the piston with the front mark on the piston crown facing the front of the engine using Tool
CAUTION: Be careful not to damage the crankshaft pin, resulting from an interference of the connecting rod big end.
14. Install the connecting rod caps. Assemble the components in their original positions.
^ Match the stamped cylinder number marks on the connecting rod with those on the cap to install.
15. Tighten the connecting rod bolts using Tool in four steps as follows:
^ Apply engine oil to the threads and seats of the connecting rod bolts.
CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.
Step 1: 18.6 - 20.6 Nm (1.9 - 2.1 kg-m, 14 - 15 ft. lbs.)
Step 2: 85° - 95° (target 90° degrees)
^ Check the connecting rod side clearance. Refer to CONNECTING ROD SIDE CLEARANCE.
^ After tightening the bolts, make sure that the crankshaft rotates smoothly.
16. Install flywheel (M/T Models), or drive plate (A/T Models).
^ Install drive plate, reinforcement plate and pilot converter as shown in figure.
^ Using a drift with 33 mm (1.30 inch) diameter, push pilot converter into the end of the crankshaft.
17. Install the cylinder block heater.
Cylinder block heater: 69 - 78 Nm (7.0 - 8.0 kg-m, 51 - 57 ft. lbs.)
18. Install the knock sensor.
^ 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 lower left by 45° as shown.
^ Do not tighten the knock sensor bolt while holding the connector.
^ Make sure that the knock sensor does not interfere with other components.
Knock sensor bolt: 15.7 - 26.5 Nm (1.6 - 2.7 kg-m, 12 -19 ft. lbs.)
CAUTION: If the knock sensor is dropped, replace it with new one.
19. Install the crankshaft position sensor (POS).
Crankshaft position sensor bolt: 5.4 - 7.3 Nm (0.55 - 0.75 kg-m, 48 - 65 inch lbs.)
20. Installation of remaining components is in reverse order of removal.