Disassembly And Assembly

CYLINDER BLOCK


Disassembly and Assembly


DISASSEMBLY
1. Remove cylinder head. Removal and Replacement.
2. Remove knock sensor.

CAUTION:
Carefully handle knock sensor avoiding shocks.
3. Remove crankshaft position sensor (POS) and cover.

CAUTION:
- Avoid impacts such as a dropping.
- Never disassemble.
- Keep it away from metal particles.
- Never place the sensor where it is exposed to magnetism.
4. Remove piston and connecting rod assembly with the following procedure:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Inspection.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.





c. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.

CAUTION:
- Be careful not to damage matching surface with connecting rod cap.
- Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
5. Remove connecting rod bearings.

CAUTION:
Identify installation positions, and store them without mixing up.
6. Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Inspection.





- Use suitable tool (A).

CAUTION:
- When removing piston rings, be careful not to damage the piston.
- Be careful not to damage piston rings by expanding them excessively.
7. Remove piston from connecting rod.





- Use Tool and a press to remove the piston pin.






CAUTION:
Be careful not to damage the piston and connecting rod.

NOTE:
The joint between the connecting rod and the piston pin is a press fit.
8. Remove the main bearing cap in the following procedure.
- Measure crankshaft end play before loosening main bearing cap bolts. Inspection






Arrow Indicates Engine Front


a. Loosen and remove bolts in several steps in reverse of the numerical order shown.


- TORX socket (size: E14) can be used.
b. Label parts for assembly and remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.

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





9. Remove crankshaft (2).

CAUTION:
- Be careful not damage or deform signal plate (1) mounted on crankshaft.
- When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface.
- Never remove signal plate unless it is necessary to do so.

NOTE:
When removing or installing signal plate, use TORX socket (size
T40).
10. Pull rear oil seal out from rear end of crankshaft.
11. Label parts for assembly and remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing cap.

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

ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.

WARNING:
Use goggles to protect your eyes.






Arrow Indicates Engine Front

2. Install water drain plug (1) to cylinder block as shown.


Use Genuine Silicone RTV Sealant or equivalent. Recommended Chemical Products And Sealants.
3. Install main bearings and thrust bearings in their original positions with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.






Arrow Indicates Engine Front

b. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block.


- Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).





c. Install the main bearings (1) paying attention to the direction.
- Install the one with oil holes (A) onto cylinder block and the one without oil holes onto main bearing cap.
- Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
- Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.










- Install the main bearing in the position shown.

NOTE:
Install the main bearing in the center position with the following dimension. For service operation, the center position can be checked visually.






CAUTION:
Dimension L1 of journal No. 3 is the distance from the housing base end surface (bulk) (not the distance from the thrust bearing mounting end surface).
4. Install signal plate to crankshaft if removed.










a. Set the signal plate (1) with the flange facing toward the counterweight side (engine front side) to the crankshaft rear surface.
b. After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt.

NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for each.
c. Remove dowel pin.

CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block.
- Make sure that crankshaft turns smoothly by hand.

CAUTION:
Never install rear oil seal yet.
6. Install main bearing caps in their original positions.






Arrow Indicates Engine Front

- Install the main bearing cap while referring to the front mark
(B) and the journal number stamp (A).


NOTE:
Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.






Arrow Indicates Engine Front

7. Tighten main bearing cap bolts in numerical order shown with the following steps.


a. Apply new engine oil to threads and seat surfaces of the bolts.
b. Tighten main bearing cap bolts in the numerical order shown.











c. Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order shown.

CAUTION:
Check and confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool.







- After installing the bolts, make sure that crankshaft can be rotated smoothly by hand.
- Check crankshaft end play. Inspection.
8. Install piston to connecting rod with the following procedure:










a. Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position shown.

NOTE:
The symbols without notes are for management.









b. Press-fit the piston pin using Tool.






CAUTION:
Press-fit the piston so as not to damage it.

NOTE:
The joint between the connecting rod and the piston pin is a press fit.









- Press-fit the piston pin (2) from piston surface "A" to the depth of 2.35 mm (0.092 in).
- After finishing work, make sure that the piston (3) moves freely.
9. Using a suitable tool, install piston rings.

CAUTION:
- Be careful not to damage piston.
- Be careful not to damage piston rings by expanding them excessively.









- Position each ring with the gap as shown referring to the piston front mark (B).
- Install second ring with the stamped mark (E) facing upward.






10. Install connecting rod bearings to connecting rod and connecting rod cap.
- When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
- Install the bearing in the center position.

NOTE:
There is no stopper tab.
- Make sure that the oil holes on connecting rod and connecting rod bearing are aligned.









- Install the connecting rod in the dimension shown.






NOTE:
Install the connecting rod bearing in the center position with the dimension shown. For service operation, the center position can be checked visually.
11. Install piston and connecting rod assembly to crankshaft.
- Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
- Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
- Match the cylinder position with the cylinder number on connecting rod to install.





- Using Tool (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine.

CAUTION:
- Be careful not to damage matching surface with connecting rod cap.
- Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.






12. Install connecting rod cap.









- Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.

13. Inspect outer diameter of connecting rod cap bolts. Inspection.
14. Tighten connecting rod bolt with the following procedure:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts in several steps.










c. Then turn all bolts 60 degrees clockwise (angle tightening).

CAUTION:
Confirm the tightening angle by using Tool (A) or protractor.
Avoid judgment by visual inspection without the tool.






- After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
- Check the connecting rod side clearance. Inspection.
15. Install oil pan (upper). Removal And Installation.

NOTE:
Install the rear oil seal after installing the oil pan (upper).
16. Install rear oil seal. Service and Repair.
17. Install flywheel or driveplate.
- Secure flywheel or drive plate with Tool, and tighten bolts crosswise over several times.











Arrow Indicates Engine Front

18. Install knock sensor (1).


- Install connectors so that they are positioned towards the rear of the engine.

CAUTION:
- Never tighten bolt while holding the connector.
- If any impact by dropping is applied to knock sensor, replace it with a 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.
19. Install crankshaft position sensor (POS) and cover.
- Tighten bolts with it seated completely.





20. For the oil level gauge guide (1), fix the position (B) shown to the water inlet clip (A) after inserting to the cylinder block side.
21. Assembly is in the reverse order of disassembly after this step.