Disassembly And Assembly
CYLINDER BLOCK
Disassembly and Assembly
DISASSEMBLY
1.Remove the following parts:
- Oil pans (lower and upper): Exploded View.
- Front and rear timing chain case: Exploded View and Exploded View.
- Cylinder head: Exploded View.
2.Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
3.Remove baffle plate from lower cylinder block.
4.Remove piston and connecting rod assembly with the following procedure:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
Inspection.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a.Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b.Remove connecting rod bearing 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 the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
5.Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
- Be careful not to drop connecting rod bearing, and to scratch the surface.
- Identify installation positions, and store them without mixing them up.
6.Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Inspection.
- Use a piston ring expander (commercial service tool) (A).
CAUTION:
- When removing piston rings, be careful not to damage piston.
- Be careful not to damage piston rings by expanding them excessively.
7.Remove piston from connecting rod as follows:
a.Using snap ring pliers (A), remove snap rings.
b.Heat piston to 60 to 70�C (140 to 158�F) with an industrial use dryer (A) or equivalent.
c.Push out piston pin using a stick than has an outer diameter of approximately 20 mm (0.79 in).
8.Remove lower cylinder block bolts.
- Before loosening lower cylinder block bolts, measure the crankshaft end play. Inspection.
- Loosen lower cylinder block bolts in the reverse order shown in the figure in several different steps.
9.Remove lower cylinder block as follows:
Screw M8 bolt [pitch: 1.25 mm (0.0492 in) length: approximately
50 mm (1.97 in)] into bolt holes (A). Then equally tighten each bolt, and remove lower cylinder block.
CAUTION:
- Be careful not to damage the mounting surfaces.
- Never tighten bolts excessively.
- Never insert screwdriver, this will damage the mating surface.
10.Remove crankshaft.
11.Pull rear oil seal out from rear end of crankshaft.
12.Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
- Be careful not to drop main bearing, and to scratch the surface.
- Identify installation positions, and store them without mixing them up.
13.Remove oil jet.
ASSEMBLY
CAUTION:
Do not reuse O-rings or washers.
1.Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
CAUTION:
Use goggles to protect your eyes.
2.Install each plug to cylinder block as shown in the figure.
- Apply sealant to the thread of water drain plug (1).
Use Genuine RTV Silicone Sealant or equivalent. Refer to
Recommended Chemical Products And Sealants.
- Apply sealant to the thread of plug (4).
Use Genuine High Strength Thread Locking Sealant or equivalent. Recommended Chemical Products And Sealants.
- Replace washers (2) with new ones.
CAUTION:
Do not reuse washers.
- Tighten each plug as specified below.
Unit: Nm (kg-m, ft-lb)
3.Install oil jet.
- Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
4.Install main bearings and thrust bearings as follows:
CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
a.Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
b.Install thrust bearings (1) to both sides of the No. 3 journal housing on cylinder block.
- Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).
c.Install main bearings paying attention to the direction.
- Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on lower cylinder block.
- Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
- When installing, align main bearing stopper protrusion to cutout of cylinder block and lower cylinder block.
- Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5.Install crankshaft to cylinder block.
- While turning crankshaft by hand, check that it turns smoothly.
6.Install lower cylinder block.
CAUTION:
Do not reuse O-rings.
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.
- Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to lower cylinder block as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
Recommended Chemical Products And Sealants.
7.Inspect the outer diameter of lower cylinder block bolt. Inspection.
8.Install lower cylinder block bolts as follows:
a.Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
b.Tighten bolts (No. 17 to 26) in numerical order as shown in the figure.
c.Repeat step b.
d.Tighten bolts (No. 1 to 16) in numerical order as shown in the figure.
NOTE:
Use TORX socket for bolts No.1 to 16.
e.Turn bolts (No. 1 to 16) 90 degrees clockwise (angle tightening).
CAUTION:
Use the angle wrench [SST: KV-10112100 (BT-8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
- After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.
- Check the crankshaft end play. Inspection.
9.Install piston to connecting rod as follows:
a.Using snap ring pliers, install new snap ring to the groove of piston rear side.
- Insert it fully into groove to install.
b.Install piston to connecting rod.
- Using an industrial use dryer or similar tool, heat piston until 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 on the piston head and the cylinder number on connecting rod are positioned as shown in the figure.
c.Install new snap ring to the groove of the piston front side.
- Insert it fully into groove to install.
- After installing, check that connecting rod moves smoothly.
10.Using a piston ring expander (commercial service tool) (A), install piston rings.
CAUTION:
- When installing piston rings, be careful not to damage piston.
- Be careful not to damage piston rings by expending them excessively.
- If there is stamped mark on ring, mount it with marked side up.
- Position each ring with the gap as shown in the figure referring to the piston front mark (D).
- Check the piston ring side clearance. Inspection.
11.Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
- Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
- When installing, align connecting rod bearing stopper protrusion (B) with cutout (C) of connecting rods and connecting rod bearing caps to install.
- Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
12.Install piston and connecting rod assembly to crankshaft.
- Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
- Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
- Match the cylinder position with the cylinder number on connecting rod to install.
- Be sure that front mark on piston crown is facing the front of the engine.
- Using a piston ring compressor [SST: EM-03470000 (J-8037)]
(A) or suitable tool, install piston with the front mark on the piston crown 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.
13.Install connecting rod bearing cap.
- Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
- Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.
14.Tighten connecting rod bolt as follows:
a.Inspect the outer diameter of connecting rod bolt. Inspection.
b.Apply engine oil to the threads and seats of connecting rod bolts.
c.Tighten connecting rod bolts.
d.Completely loosen connecting rod bolts.
e.Tighten connecting rod bolts.
f.Then turn connecting rod bolts 90 degrees clockwise (angle tightening).
CAUTION:
Always use the angle wrench [SST: KV-10112100 (BT-8653A)] (A). Never make judgment by visual inspection.
- After tightening connecting rod bolts, check that crankshaft rotates smoothly.
- Check the connecting rod side clearance. Inspection.
15.Install baffle plate.
16.Install new rear oil seal. Service and Repair.
- Apply new engine oil to both oil seal lip and dust seal lip.
17.Install pilot converter (A/T models) or pilot bushing (M/T models).
- With a drift of the following outer diameter, press-fit as far as it will go.
Pilot bushing: Approximately 17 mm (0.67 in)
Pilot converter: Approximately 33 mm (1.30 in)
- Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)
- Press-fit pilot bushing (1) as the dimension shown in the figure. (M/T models)
18.Install knock sensors.
- Install knock sensor so that connector faces the rear of the engine.
- After installing knock sensor, connect harness connector, and lay it out to rear of the engine.
CAUTION:
- Never tighten mounting bolts while holding connector.
- If any impact by dropping is applied to knock sensor, replace it with new one.
NOTE:
- Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
- Check that knock sensor does not interfere with other parts.
19.Note the following, assemble in the reverse order of disassembly after this step.
- Ensure the dowel pin (1) is installed in the crankshaft.
- When installing flywheel (3) to crankshaft (2), be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole (A).
- There is a matching mark (B) on the clutch cover side of flywheel (4). Refer it during installation.
- When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
CAUTION:
If these are not aligned correctly, engine runs roughly and "MIL" illuminates.
- Install drive plate (2) and reinforcement plate (3) as shown in the figure.
- Holding ring gear with the ring gear stopper [SST: KV-10118600 (J-48641)].
- Tighten the mounting bolts crosswise over several times.