Part 1
Cylinder BlockREMOVAL
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 timing 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.
11. Remove the flywheel. (MT model)
12. Remove drive plate. (AT model)
Using 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.
ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 inch))
ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 inch))
16. Remove the oil cooler.
17. Remove the water pump.
18. Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing the oil pump.
NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump.
19. 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 an oil pan cutter blade between cylinder block-to-oil pan clearance, and then remove the oil pan.
Do not use a screwdriver or similar tool in place of oil pan cutter.
20. Remove the oil strainer stay.
21. Remove the oil strainer.
22. Remove the baffle plate.
23. Remove the water pipes.
24. Remove the service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 inch)].
25. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and 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 499097700 PISTON PIN REMOVER
CAUTION: Be careful not to change 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 the cylinder block on the side of #2 and #4 cylinders.
29. Back off the bolts which connect the 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 cylinder blocks (LH) and (RH).
NOTE: 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 change 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 change the combination of piston and cylinder.
B: INSTALLATION
CAUTION:
^ Remove oil in the mating surface of bearing and cylinder block before installation.
^ Also apply a coat of engine oil to crankshaft pins.
1. Install the crankshaft on the cylinder block and apply a thin coat of engine oil to the crankshaft bearing, and then position crankshaft on the #2 and #4 cylinder block.
2. Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent
CAUTION: When applying fluid gasket, do not allow fluid packing to overflow to O-ring grooves, oil passages, bearing grooves, etc.
3. Apply engine oil to washers and thread of bolts.
4. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side)
Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft. lbs.)
5. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side)
Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft. lbs.)
6. Further tighten the LH side bolts (A-D) in alphabetical sequence.
Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft. lbs.)
7. Further tighten the RH side bolts (E-J) in alphabetical sequence.
Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft. lbs.)
8. Further tighten the LH side bolts (A and C) by 90° in alphabetical sequence. And further tighten bolts (B and D) in alphabetical sequence.
Tightening torque: (B), (D): 40 Nm (4.1 kgf-m, 29.5 ft. lbs.)
9. Further tighten the RH side bolts (E-J) by 90° in alphabetical sequence.
10. Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure.
Tightening torque:
(A)-(G): 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
11. Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
12. Position the top ring gap at (A) or (B) in the figure.
13. Position the second ring gap at 180° on the reverse side for the top ring gap.
14. Position the upper rail gap at (c) in the figure.
15. Align upper rail spin stopper (E) with piston side surface hole (D).
16. Position the expander cap at (F) in the figure.
17. Position the lower rail gap at (G) in the figure.
CAUTION:
^ Ensure ring gaps do not face the same direction.
^ Ensure ring gaps are not within the piston skirt area.
18. Install the circlip. Install the circlips in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders.
NOTE: Use new circlips.
19. Installing the piston:
a Turn the cylinder block so that #1 and #2 cylinders face upward.
b Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
c Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.
ST2 498747300 PISTON GUIDE
CAUTION: Piston front mark faces towards the front of the engine.
20. Installing piston pin:
a Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end.
ST3 499017100 PISTON PIN GUIDE
b Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole.
c Using the ST, install the circlip.
NOTE: Use new circlips.
d Apply fluid packing around the service hole plug.
Fluid packing:
Part No. 004403007
THREE BOND 1215 or equivalent
e Install the service hole plug and gasket.
NOTE: Use a new gasket.
f Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
21. Install the water pipe.
22. Install the baffle plate.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
23. Install the oil strainer and O-ring
Tightening torque: 10 Nm (1.0 kgf-m, 7 ft. lbs.)
24. Install the oil strainer stay.
25. Apply fluid packing to the matching surfaces, and then install the oil pan.
NOTE: Install the oil pan within 20 minutes after applying fluid packing.
Fluid packing:
Part No. 004403012
THREE BOND 1207C or equivalent
Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.)
26. Apply fluid packing to the matching surfaces and the bolt thread (A) as shown in the figure, and then install the oil separator cover.
NOTE: Install the oil pan within 20 minutes after applying fluid packing.
Fluid packing:
Part No. 004403012
THREE BOND 1270C or equivalent
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
27. Install the flywheel.
28. Install the clutch disc and cover.
29. Installation of oil pump:
a Discard the front oil seal after removal. Replace with a new one using the ST.
ST 499587100 OIL SEAL INSTALLER
b Apply fluid packing to the matching surface of oil pump.
Fluid packing:
Part No. 004403007
THREE BOND 1215 or equivalent
c Apply a coat of engine oil to the inside of the oil seal.
d Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
CAUTION:
^ Install the O-ring and seal securely when installing the oil pump.
^ Align the flat surface of oil pump's inner rotor with crankshaft before installation.
30. Install the water pump and gasket.
Tightening torque:
First, 12 Nm (1.2 kgf-m, 8.7 ft. lbs.)
Second, 12 Nm (1.2 kgf-m, 8.7 ft. lbs.)
CAUTION:
^ Be sure to use a new gasket.
^ When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure.
31. Install the water by-pass pipe for heater.
32. Install the oil cooler.
Tightening torque:
T1: 45 Nm (4.6 kgf-m, 33 ft. lbs.)
T2: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
T3: 54 Nm (5.3 kgf-m, 39 ft. lbs.)
33. Prepare oil filter and apply a thin coat of engine oil to the seal rubber.
34. Install the oil filter using ST.
ST 18332AA000 OIL FILTER WRENCH [Outer diameter: 68 mm (2.68 inch) for oil filter]
ST 18332AA010 OIL FILTER WRENCH [Outer diameter: 65 mm (2.56 inch) for oil filter]
When installing oil filter, carefully turn by hand so as not to damage seal rubber.
^ Oil filter with 68 mm (2.68 inch) outer diameter is further tightened (about 1 rotation) with ST after seal rubber contacts an oil cooler.
^ Oil filter with 65 mm (2.56 inch) outer diameter is further tightened (about 2/3 to 3/4 rotation) with ST after seal rubber contacts an oil cooler.
CAUTION:
^ Do not tighten excessively, or oil may leak.
^ It must be noted that oil filter with 80 mm (3.15 inch) outer diameter is not available for TURBO model.
35. Install the water by-pass pipe between oil cooler and water pump.
36. Install the water pipe.
CAUTION: Always use a new O-ring.
37. Install the cylinder head assembly.
38. Install the oil level gauge guide and tighten the attaching bolt (LH side).
39. Install the rocker cover.
40. Install the crankshaft sprocket.
41. Install the camshaft sprocket.
42. Install the timing belt assembly.
43. Install the timing belt cover.
44. Install the crankshaft pulley.
45. Install the generator and A/C compressor brackets on cylinder head.
46. Install the V-belt.
47. Install the intake manifold.