Disassembly And Assembly
CYLINDER BLOCK
Disassembly and Assembly
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Component Removal And Installation.
2. Install engine to engine stand as follows;
a. Remove flywheel (M/T models) or drive plate (1) (A/T or CVT models).
- Secure flywheel (M/T models) or drive plate (A/T or CVT models) using Tool (A), and remove bolts.
CAUTION:
Be careful not to damage or scratch drive plate (A/T or CVT models) and contact surface for clutch disc of flywheel (M/T models).
NOTE:
Figure shows drive plate (1) (A/T or CVT models)
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
- Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large enough for supporting the engine weight.
- If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand.
- Exhaust manifold; Component Removal And Installation.
- Rocker cover; Component Removal And Installation.
NOTE:
The figure shows an example of widely used engine stand (A) that can support mating surface of transaxle with flywheel (M/T models) or drive plate (A/T or CVT models) removed.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
3. Remove oil pan (upper and lower). Component Removal And Installation.
4. Remove cylinder head. Testing and Inspection.
5. Remove thermostat housing. Component Removal and Installation.
6. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
CAUTION:
- Avoid impacts such as a dropping.
- Never disassemble.
- Keep it away from metal particles.
- Never place sensor in a location where it is exposed to magnetism.
8. Remove oil filter (for intake valve timing control).
9. Remove pilot converter (1) using Tool (A). (A/T or CVT models)
NOTE:
M/T models have no pilot converter.
10. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
NOTE:
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Inspection After Disassembly.
11. Remove connecting rod cap.
12. Using a suitable 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.
13. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
14. Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Inspection After Disassembly.
15. Using a suitable tool (A) remove piston rings.
CAUTION:
- When removing piston rings, be careful not to damage the piston.
- Be careful not to damage piston rings by expanding them excessively.
16. Using snap ring pliers (A), remove snap rings.
17. Heat piston to 60� to 70�C (140� to 158�F) using a suitable tool
(A).
18. Push out piston pin using a suitable tool of an outer diameter approximately 18 mm (0.71 in).
Arrow Indicates Engine Front
19. Loosen main bearing cap bolts in reverse order as shown, and remove them.
NOTE:
Before loosening main bearing cap bolts, measure crankshaft end play. Inspection After Disassembly.
20. Remove main bearing caps.
- Tap main bearing caps lightly using a suitable tool for removal.
CAUTION:
Be careful not to damage the mounting surface.
21. Remove crankshaft.
CAUTION:
- Be careful not to damage or deform signal plate (1) mounted on rear end of crankshaft (A).
- 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.
22. Pull rear oil seal out from rear end of 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.
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.
- Apply liquid gasket to the drain plug thread.
Use Genuine Silicone RTV Sealant or equivalent. Recommended Chemical Products And Sealants.
3. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
Arrow Indicates Engine Front
4. Install thrust bearings to both sides of the No. 3 journal housing
(B) on cylinder block.
- Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
5. Install the main bearings paying attention to the direction.
CAUTION:
- Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new engine oil to the back surface, but thoroughly clean it.
- When installing, align main bearing to the center position of cylinder block and main bearing cap.
- The difference (A) between main bearing upper (1) and main bearing lower (3) should be 0.85 mm (0.033 in) or less when installing.
- Ensure the oil holes on cylinder block and oil holes (A) on the main bearings (1) are aligned.
6. Install signal plate to crankshaft if removed.
7. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crankshaft rear surface.
8. Apply new engine oil to threads and seat surfaces of bolts.
9. Position crankshaft (2) and signal plate (1) using a dowel pin
(service part), and tighten bolts in numerical order as shown.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for each.
10. Tighten bolts in numerical order as shown.
11. Remove dowel pin. (service parts)
CAUTION:
Be sure to remove dowel pin.
12. Install crankshaft to cylinder block.
- While turning crankshaft by hand, make sure that it turns smoothly.
Arrow Indicates Engine Front
13. Install main bearing caps referring to the journal No. stamp (A) and front mark (B) as shown.
NOTE:
Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
14. Apply new engine oil to threads and seat surfaces of bolts.
Arrow Indicates Engine Front
15. Tighten main bearing cap bolts in two steps in numerical order as shown.
CAUTION:
Measure the angle in step 2 using Tool (A). Do not measure visually.
- After installing bolts, make sure that crankshaft can be rotated smoothly by hand.
- Check crankshaft end play. Inspection After Disassembly.
16. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
- Insert it fully into groove to install.
17. Assemble piston to connecting rod.
- Using a suitable tool, heat the piston until the 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 (A) on the piston head and the oil hole (B) and the cylinder number (C) on connecting rod are positioned as shown.
18. 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.
19. 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.
CAUTION:
Never contact the rail end gap under the oil ring with the oil drain cast groove of piston.
- Install second ring with the stamped surface facing upward.
20. Install connecting rod bearing upper (2) and lower (3) to connecting rod (1) and connecting rod cap (4).
- Install the connecting rod in the dimension shown.
- Make sure that connecting rod bearing oil hole (A) is completely in the inside of connecting rod oil hole chamfered area
(B).
- When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply new engine oil to the back surface, but thoroughly clean it.
NOTE:
- There is no positioning tab.
- Install the connecting rod bearings in the center of connecting rod and connecting rod bearing cap as shown. For service operation, the center position can be checked, visually.
21. 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 (C) on connecting rod to install.
- Install so that front mark (A) on the piston head faces the front of engine.
- Using Tool (A), install piston with the front mark on the piston head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
22. Install connecting rod cap.
- Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.
23. Tighten connecting rod bolt with the following procedure:
CAUTION:
- Make sure that there is no gap in the thrust surface (A) of the joint between connecting rod (1) and connecting rod bearing cap (2) and that these parts are in the correct position. And then, tighten the connecting rod bolts.
- If the connecting rod bolts are reused, measure the outer diameter. Inspection After Disassembly.
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts in two steps using Tool.
- After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.
- Check the connecting rod side clearance. Inspection After Disassembly.
24. Install oil pan (upper). Component Removal And Installation.
NOTE:
Install the rear oil seal after installing the oil pan (upper).
25. Install rear oil seal. Component Removal And Installation.
26. Install flywheel (M/T models) or drive plate (1) (A/T or CVT models).
- Secure crankshaft using Tool (A), and tighten bolts crosswise over several times.
NOTE:
A/T model shown CVT and M/T similar.
- Install pilot converter (3), drive plate (1) and reinforcement plate (2) as shown (A/T or CVT models).
- Using a suitable tool of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it stops (A/T or
CVT models).
NOTE:
M/T models have no pilot converter and reinforcement plate.
27. Install knock sensor (1) with connector facing toward the rear of engine.
CAUTION:
- Never tighten bolts 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.
28. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.
CAUTION:
- Avoid impacts such as a dropping.
- Keep it away from metal particles.
- Never place sensor in a location where it is exposed to magnetism.
29. Install oil filter (for intake valve timing control) (1) in the direction shown.
- Make sure that the oil filter does not protrude from the upper surface of cylinder block (2) after installation.
30. Assembly is in the reverse order of disassembly.