Disassembly And Assembly

CYLINDER BLOCK

Disassembly and Assembly

DISASSEMBLY

NOTE:
The following procedures explain how to disassemble the engine with the engine stand fastened to the bell housing. Some steps may be different if using a different type of engine stand.
1.Remove cylinder head. Exploded View.
2.Remove knock sensor.

CAUTION:
Carefully handle knock sensor avoiding shocks.

3.Remove the crankshaft position sensor cover (3), and then crankshaft position sensor (POS) (2).

CAUTION:
- Avoid impacts such as a dropping.
- Never disassemble.
- Keep sensor away from metal particles.
- Never place the sensor in a location where it is exposed to magnetism.
- Do not reuse O-ring.
4.Remove oil pan (upper and lower). Exploded View.
5.Remove piston and connecting rod assembly:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
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 through the cylinder head side.

CAUTION:
- Be careful not to damage mating surface with connecting rod cap.
- Be careful not to damage the cylinder wall or crankshaft pin.
6.Remove connecting rod bearings.

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

- Use a suitable tool) (A) as shown.

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

- Use a Tools (A, B, C) and a press to remove the piston pin.

CAUTION:
- Never damage the piston and connecting rod.
- Do not reuse piston and piston pin after removing piston pin from connecting rod.
- The connecting rod is reusable.
NOTE:
The joint between the connecting rod and the piston pin is a press fit.
9.Remove the main bearing cap.
- Measure crankshaft end play before loosening main bearing cap bolts. Inspection.

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

NOTE:
When removing or installing signal plate, use TORX socket (size
T40).
b.Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.

10.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).
11.Pull rear oil seal out from rear end of crankshaft.
12.Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing caps.

CAUTION:
Identify original installation positions, and store the bearings without mixing them up.
13.Remove oil jets.

CAUTION:
Insert the dowel pin of oil jet into the cylinder block dowel pin hole to loosen the mounting bolt.

ASSEMBLY

CAUTION:
Do not reuse O-rings.
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.
2.Install oil jets.
3.Install main bearings and thrust bearings:
a.Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.

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 paying attention to the direction.
- 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.
- When installing, align main bearing to the center position of cylinder block and main bearing cap.

- Ensure the oil holes on cylinder block and oil holes (A) on the main bearings (1) are aligned.
NOTE:
For assembly, the center position can be visually identified.
- To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off the cylinder block chamfer.
- To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off bearing cap chamfer.
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.
- While turning crankshaft by hand, check that it turns smoothly.

CAUTION:
Do not install rear oil seal at this time.
6.Install main bearing caps.

- 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.

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

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

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

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

Tool number: KV-10112100 (BT-8653-A)

- After installing the main bearing cap bolts, check 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 as shown.

NOTE:
The symbols without notes are for manufacturing.

b.Press-fit the piston pin using the Tools (A, B, C, D, E).

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) (b).

- After finishing work, check that the piston (3) moves freely.

9.Using suitable tool (A), 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.
- Check that the oil holes on connecting rod and connecting rod bearing are aligned.

- Install the connecting rod in the dimension (A) as shown.

NOTE:
Install the connecting rod bearing in the center position with the dimension as 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 mating surface with connecting rod cap.
- Be careful not to damage the cylinder wall or crankshaft pin.
Tool number: EM-03470000
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 bolts. Inspection.
14.Tighten connecting rod bolt:
a.Apply new engine oil to the threads and seats of connecting rod bolts.
b.Tighten connecting rod bolts in several steps.

c.Completely loosen connecting rod bolts.

d.Tighten connecting rod bolts in several steps.

e.Then turn all connecting rod bolts 60 degrees clockwise (angle tightening).

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

Tool number: KV-10112100 (BT-8653-A)

- After tightening connecting rod bolt, check that crankshaft rotates smoothly.
- Check the connecting rod side clearance. Inspection.
15.Install oil pan (upper). Exploded View.
NOTE:
Install the rear oil seal after installing the oil pan (upper).
16.Install rear oil seal. Service and Repair.
17.Install flywheel (M/T models) or drive plate (CVT models).

- Secure crankshaft with a stopper plate (A) and tighten mounting bolts crosswise over several times.

Tool number: KV-11105210 (J-44716)

- Secure crankshaft with a stopper plate (A) and tighten mounting bolts crosswise over several times.

Tool number: KV-11105210 (J-44716)

CAUTION:
Be careful not to damage or scratch and contact surface for clutch disc of flywheel.

18.Install knock sensor (1).

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

CAUTION:
- Never tighten mounting bolt while holding the connector.
- If any impact by dropping is applied to knock sensor, replace it with a 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.Install crankshaft position sensor (POS) (2) using a new O-ring (1) and then install the crankshaft position sensor cover (3) on the cylinder block (4).
- Tighten bolts with sensor inserted completely.

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