Removal

REMOVAL

NOTE: Before conducting this procedure, drain the engine oil completely if applicable.

1) Remove the intake manifold.
2) Remove the V-belt.
3) Remove the crankshaft pulley.
4) Remove the belt cover.
5) Remove the timing belt assembly.
6) Remove the camshaft sprocket.
7) Remove the crankshaft sprocket.
8) Remove the generator and A/C compressor with their brackets.
9) Remove the cylinder head assembly.
10) Remove the clutch disc and cover. (MT vehicles)
11) Remove the flywheel. (MT vehicles)





12) Remove the drive plate. (AT vehicles) Using the ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
13) Remove the oil separator cover.
14) Remove the water by-pass pipe for heater.
15) Remove the oil filter.





16) Remove the oil cooler.
17) Removal of oil pan:
a) Turn the cylinder block with #2 and #4 piston sides facing upward.
b) Remove the bolts which secure oil pan to cylinder block.





c) Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.

CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.

18) Remove the oil strainer stay.
19) Remove the oil strainer.
20) Remove the baffle plate.
21) Remove the water pipes.
22) Remove the water pump.





23) Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing the oil pump.

CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.








24) Remove the service hole cover and service hole plugs using the hexagon wrench [14 mm (0.55 inch)].





25) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston circlip through service hole of #1 and #2 cylinders.





26) Draw out the piston pin from #1 and #2 pistons using ST.
ST 499097600 PISTON PIN REMOVER

CAUTION: Be careful not to confuse the original combination of piston, piston pin and cylinder.





27) Similarly remove the piston pins from #3 and #4 pistons.
28) Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
29) Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
30) Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
31) Separate the left-hand and right-hand cylinder blocks.

CAUTION: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.

32) Remove the rear oil seal.
33) Remove the crankshaft together with connecting rod.
34) Remove the crankshaft bearings from cylinder block using a hammer handle.

CAUTION: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.

35) Draw out each piston from cylinder block using a wooden bar or hammer handle.

CAUTION: Do not confuse the combination of piston and cylinder.