Disassembly And Assembly
CYLINDER BLOCK
Disassembly and Assembly
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. Refer to Service and Repair.
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. Refer to Service and Repair.
- Intake manifold collector. Refer to Service and Repair.
- Intake manifold and fuel tube assembly. Refer to Service and Repair.
- Ignition coils. Refer to Service and Repair.
- Rocker cover. Refer to Service and Repair.
- Front cover, timing chain, and balancer unit. Refer to Service and Repair.
- Cylinder head. Refer to Removal and Replacement.
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 drive plate. Hold the crankshaft with a stopper plate and use a suitable tool to remove the bolts.
CAUTION:
- Be careful not to damage the drive plate.
8. 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 Inspection.
9. 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.
10. 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 Inspection.
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.
11. 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 in).
12. Remove the lower cylinder block bolts.
- Before loosening the lower cylinder block bolts, measure the crankshaft side clearance. Refer to Inspection.
- Loosen them in the order as shown to remove them.
13. Remove the lower cylinder block.
- Cut the Silicone RTV Sealant and remove the lower cylinder block from the cylinder block, using Tool.
Seal cutter KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mating surface.
14. 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.
15. 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.
16. 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.
WARNING:
Use approved safety glasses to protect your eyes.
2. Be sure the grommet (1) is installed flush with the flange plane as shown prior to mating the engine and transaxle.
CAUTION:
Do not use lubricating oil for lubricant.
NOTE:
Be careful that the edge does not protrude from the socket.
3. Install the drain plugs on the cylinder block.
- Apply Silicone RTV Sealant.
Use Genuine Silicone RTV Sealant, or equivalent. Refer to Fluid Type Specifications.
- Replace the copper washers with new ones.
- :Arrow indicates Front
4. 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 (D, G) paying attention to their position and direction.
- The main bearing (C) with an oil hole and groove goes on the cylinder block. The main bearing (H) without them goes on the lower cylinder block.
- Only the main bearing (D) (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 (B) to the notch.
- Make sure that the oil holes on the cylinder block and those on the corresponding bearing (A) are aligned.
5. Install the signal plate to the crankshaft.
a. Position the crankshaft and signal plate using a positioning dowel pin, and tighten the bolts to specification.
b. Remove the dowel pin.
CAUTION:
Be sure to remove dowel pin before installing the crankshaft.
NOTE:
Dowel pins for the crankshaft and signal plate are supplied as a set for each.
6. Install the crankshaft onto the cylinder block.
- While turning the crankshaft by hand, check that it turns smoothly.
7. Install the lower cylinder block.
- Apply Silicone RTV Sealant to positions as shown.
- Use Genuine Silicone RTV Sealant, or equivalent. Refer to Fluid Type Specifications.
CAUTION:
After the Silicone RTV Sealant is applied, the lower cylinder block installation must be finished within 5 minutes.
NOTE:
Cylinder block and lower cylinder block are machined together. Neither of them can be replaced separately.
8. Tighten lower cylinder block bolts in the numerical order as shown and according to the following steps:
CAUTION:
Check tightening angle. Do not make judgment by visual inspection.
Tool number : KV 10112100 (BT-8653-A)
a. Apply new engine oil to threads and seat surfaces of the bolts.
b. Tighten bolts No. 11 - 22 only in the order as shown, to specification below.
Step 1, bolts 11 - 22 only : 25.1 N.m (2.6 kg-m, 19 ft-lb)
c. Tighten bolts No. 1 - 10 only in the order as shown, to specification below.
Step 2, bolts 1 - 10 only : 39.2 N.m (4.0 kg-m, 29 ft-lb)
d. Tighten bolts No. 1 - 10 only in the order as shown, to specification below.
Step 3, bolts 1 - 10 only : 60�degrees rotation
- Wipe off completely any protruding Silicone RTV Sealant on rear oil seal installation surface and the exterior of engine.
- Check crankshaft side clearance. Refer to Inspection.
- After installing the bolts, make sure that the crankshaft can be rotated smoothly by hand.
9. Install the rear oil seal.
- Press the oil seal between cylinder block and crankshaft with a suitable drift.
- Be careful not to touch the grease on the oil seal lip.
- Be careful not to cause scratches or burrs when pressing in the rear oil seal.
- Press in rear oil seal to the position as shown.
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 to 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.
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, referencing the piston front mark as the starting point.
- Install the top ring and the second ring with the stamped surface facing upward.
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.
Tool number : EM03470000
- 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.
- Using a piston ring compressor, install the piston with the front mark on the piston crown facing the front of the engine.
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 bolt as follows:
Apply engine oil to the threads and seats of the connecting rod bolts.
CAUTION:
Check tightening angle. Do not make judgment by visual inspection.
Tool number : KV10112100 (BT-8653-A)
- Check the connecting rod side clearance. Refer to Inspection.
- After tightening the bolts, make sure that the crankshaft rotates smoothly.
16. Install drive plate.
- Install reinforcement plate.
- Using a drift with 33 mm (1.30 in) diameter, push pilot converter into the end of the crankshaft.
17. 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 b as shown.
- Do not tighten the bolts while holding the connector.
- Make sure that the knock sensor does not interfere with other parts.
CAUTION:
If the knock sensor is dropped, replace it with new one.
18. Install the crankshaft position sensor (POS).
19. Installation of remaining components is in the reverse order of removal.