Removal and Installation

Cylinder Block

REMOVAL
1. Remove crankshaft pulley.
2. Remove front chain cover.
3. Remove timing chain assembly.
4. Remove camshaft sprockets.
5. Remove crankshaft sprocket.
6. Remove rear chain cover.
7. Remove camshafts.
8. Remove cylinder head assembly.





9. Remove drive plate. Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER





10. Remove crankshaft position sensor plate.





11. Remove crankshaft position sensor bracket.





12. Rotate engine until oil pan comes to the top.
13. Remove bolts which secure lower oil pan to upper oil pan.
14. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan.

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





15. Remove oil strainer.





16. Remove bolts which secure upper oil pan to cylinder block.
Bolt dimension:
(A) 8 x 40
(B) 8 x 65
(C) 8 x 85
(D) 8 x 130
(E) 8 x 24





17. Remove service hole cover and service hole plugs using hexagon wrench.





18. Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders by using ST.
ST 18233AA000 PISTON PIN CIRCLIP PLIER
19. Draw out piston pin from #1 and #2 pistons by using ST.
ST 499097500PISTON PIN REMOVER





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





20. Similarly remove piston pins from #3, #4, #5 and #6 pistons.
21. Remove bolts which connect cylinder block.
22. Separate left-hand and right-hand cylinder blocks.

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

23. Remove rear oil seal.
24. Remove crankshaft together with connecting rod.
25. Remove crankshaft bearings from cylinder block using hammer handle.

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

26. Draw out each piston from cylinder block using wooden bar or hammer handle.

CAUTION: Do not confuse combination of piston, piston pin and cylinder.

INSTALLATION
1. Install ST to cylinder block, then install crankshaft bearing.
ST 18232AA000 ENGINE STAND

CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

2. Position crankshaft and connecting rod on the #2, #4 and #6 cylinder.





3. Apply fluid gasket to the mating surface of #1, #3 and #5 cylinder block.
Fluid gasket: THREE BOND 1215B or equivalent

CAUTION: Do not allow fluid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.

Fluid gasket application diameter: 1.0±0.2 mm (0.039±0.008 inch)

4. Apply engine oil to washers and threads of cylinder block connecting bolts. Tighten the bolts following the steps below.








a. Tighten all the bolts in the numerical order shown in the figure.
Tightening torque:
(1) to (11) 25 Nm (2.5 kgf-m, 18 ft. lbs.)
(12) 20 Nm (2.0 kgf-m, 14 ft. lbs.)
(13) 25 Nm (2.5 kgf-m, 18 ft. lbs.)
(14) 20 Nm (2.0 kgf-m, 14 ft. lbs.)








b. Tighten all the bolts again in the order shown in the figure.
Tightening torque:
(1) to (11) 25 Nm (2.5 kgf-m, 18 ft. lbs.)
(12) 20 Nm (2.0 kgf-m, 14 ft. lbs.)
(13) 25 Nm (2.5 kgf-m, 18 ft. lbs.)
(14) 20 Nm (2.0 kgf-m, 14 ft. lbs.)





5. Tighten all the bolts by 90° in the order shown in the figure.





6. Install upper bolts on cylinder block.
Tightening torque: 25 Nm (2.5 kgf-m, 18 ft. lbs.)





7. Install rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER





8. Positioning of piston ring.
a. Position the top ring gap at (A) in the figure.
b. Position the second ring gap at (B) in the figure.
c. Position the upper rail gap at (C) in the figure.
d. Position the expander gap at (D) in the figure.





e. Position the lower rail gap at (E) in the figure.

CAUTION:
^ Ensure ring gaps do not face the same direction.
^ Ensure ring gaps are not within the piston skirt area.

f. Install circlip. Install circlips in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders.





NOTE: Use new circlips.

9. Installing piston.

CAUTION: Install piston and piston pin to the same cylinder they were installed before overhaul.

a. Using ST1, rotate crankshaft until each small end of connecting rods #3 and #4 is aligned over service hole (A).
ST1 18252AA000 CRANKSHAFT SOCKET





b. Apply a coat of engine oil to piston and cylinders.





c. Install pistons with their front marks (A) facing the front of engine.





d. Insert pistons in their cylinders using ST2.
ST2 18254AA000 PISTON GUIDE
10. Installing piston pin.
a. Apply a coat of engine oil to ST3.
ST3 18253AA000 PISTON PIN GUIDE.





b. Insert ST3 into service hole to align piston pin hole with connecting rod small end.
c. Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod small end through service hole.
d. Using ST4, install circlip.
ST 418233AA000 PISTON PIN CIRCLIP PLIER





NOTE: Use a new circlip.

11. Repeat the same steps for pistons #1 and #2, #5 and #6.
12. Install service hole plug and cover.
13. Apply fluid gasket to mating surface of upper oil pan.





14. Install O-ring.
Fluid gasket: THREE BOND 1280B





15. Temporarily tighten the upper oil pan.

CAUTION: Do not confuse the mounting positions of the bolts.

Bolt dimension:
(A) 8 x 40
(B) 8 x 65
(C) 8 x 85
(D) 8 X 130
(E) 8 x 20





16. Tighten the upper oil pan mounting bolts in the numerical sequence shown in the figure.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





17. Install oil strainer.

NOTE: Use a new O-ring.





18. Apply fluid gasket to mating surface of lower oil pan.
Fluid gasket: THREE BOND 1280B
Fluid gasket application diameter: 5.0±1.0 mm (0.097±0.039 inch)





19. Tighten the lower oil pan mounting bolts in the numerical sequence shown in the figure.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)





20. Install crankshaft position sensor bracket.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)





21. Install crankshaft position sensor plate.





22. Install drive plate.
Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque: 81 Nm (8.3 kgf-m, 60 ft. lbs.)
23. Install cylinder head assembly.
24. Install camshafts.
25. Install rear chain cover.
26. Install crankshaft sprocket.
27. Install camshaft sprockets.
28. Install timing chain assembly.
29. Install front chain cover.
30. Install crankshaft pulley.