Disassembly and Assembly
Disassembly and Assembly
DISASSEMBLY
1. Remove engine assembly from vehicle.
2. Remove both exhaust manifolds.
3. Lift engine, and mount it onto engine stand.
^ A widely use engine stand can be used.
CAUTION: Use engine stand that has a load capacity [approximately 220 kg (441 lbs.) or more] large enough for supporting the engine weight.
4. Drain engine oil. Refer to "Changing Engine Oil".
5. Drain engine coolant by removing water drain plugs from cylinder block left side at "A" and cylinder block front side at "B" as shown in the figure.
NOTE: For Canada, "D" in the figure is not plug but block heater.
6. Remove drive plate (A/T models); using Tool.
Tool number: KV10117700 (J-44716)
^ Loosen bolts in diagonal order.
^ Use TORX socket for drive plate bolts.
CAUTION:
^ Do not disassemble drive plate (A/T models).
^ Do not place drive plate (A/T models) with signal plate facing down.
^ When handling signal plate, take care not to damage or scratch it.
^ Handle signal plate in a manner that prevents it from becoming magnetized.
7. Remove cylinder head.
8. Remove sub harness, and remove knock sensors.
CAUTION: Carefully handle sensor avoiding shocks.
9. Remove pilot converter (A/T models) using Tool as necessary Tool number: ST16610001 (J-23907)
10. Remove piston and connecting rod assembly as follows:
^ Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE".
CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface.
11. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
12. Remove connecting rod bearing cap.
13. Push piston and connecting rod assembly out to the cylinder head side using suitable tool.
CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
14. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION: Identify installation position, and store them without mixing them up.
15. Remove piston rings form piston.
^ Before removing piston rings, check the piston ring side clearance. Refer to "PISTON RING SIDE CLEARANCE".
^ Remove piston rings using piston ring expander or suitable tool.
CAUTION:
^ When removing piston rings, be careful not to damage piston.
^ Be careful not to damage piston rings by expanding them excessively.
16. Remove piston from connecting rod as follows:
a. Remove snap ring using snap ring pliers.
b. Heat piston to 60° to 70°C (140° to 158°F) with industrial use drier or equivalent.
c. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 inch).
17. Remove lower cylinder block bolts.
^ Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to "CRANKSHAFT END PLAY".
^ Loosen lower cylinder block bolts in reverse order as shown in several different steps.
NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt)
18. Remove lower cylinder block.
^ Cut liquid gasket for removal. Refer to "REMOVAL OF LIQUID GASKET SEALING".
Tool number KV10111100 (J-37228)
CAUTION: Be careful not to damage the mounting surfaces.
19. Remove crankshaft.
20. Pull rear oil seal out from rear end of crankshaft.
NOTE: When replacing rear oil seal without removing lower cylinder block, use a suitable tool to pull the rear oil seal installed between crankshaft and cylinder block out.
CAUTION: Be careful not to damage crankshaft and cylinder block.
21. 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.
22. Remove oil jet.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
CAUTION: Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown.
^ Apply sealant to the thread of water drain plugs "A" and "B".
Use Genuine RTV Silicone Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants.
^ Apply sealant to the thread of plugs "C".
Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants".
^ Apply sealant to the thread of plug "D".
Use Anaerobic Liquid Gasket or equivalent. Refer to "Recommended Chemical Products and Sealants".
NOTE: For Canada, "D" in the figure is not plug but block heater. Refer to "Disassembly and Assembly".
^ Replace washers with new one.
^ Tighten each plug as specified below.
Block Plug and Block Heater Installation
3. Install oil jet.
^ Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten bolts.
4. Install main bearings and thrust bearings as follows:
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
b. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block.
^ Install thrust bearings with the oil groove facing crankshaft arm (outside).
^ Install thrust bearing with a projection on one end on cylinder block, Align projection with mating notch.
c. Install main bearings paying attention to the direction.
^ Main bearing with oil hole and groove 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. Inspect the outer diameter of lower cylinder block bolt. Refer to "LOWER CYLINDER BLOCK BOLT OUTER DIAMETER".
7. Install lower cylinder block as follows:
NOTE: Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.
a. Apply a continuous bead of liquid gasket using Tool to lower cylinder block as shown.
Tool number: WS39930000
Use Genuine RTV Silicone Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants".
CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly.
b. Tighten lower cylinder block as follows:
i. Apply new engine oil to threads and seat surfaces of the bolts.
ii. Tighten M8 bolts in numerical order as shown from No. 17 to 24.
Bolts 17 - 24: 22.1 Nm (2.3 kg-m, 16 ft. lbs.)
CAUTION: Wipe off completely any protruding liquid gasket on rear oil seal installation surface.
NOTE: There are more processes to complete the tightening bolts. However stop procedure here to install rear oil seal.
c. Install rear oil seal. Refer to "INSTALLATION".
d. Restart tightening of lower cylinder block bolts as follows:
i. Tighten M10 bolts in numerical order as shown from No. 1 to 16.
NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
Bolts 1 - 16: 35.3 Nm (3.6 kg-m, 26 ft. lbs.)
ii. Turn M10 bolts 90° clockwise in numerical order from No. 1 to 16 using Tool.
Tool number KV10112100 (BT-8653-A)
CAUTION: Use angle wrench Tool to check tightening angle. Do not make judgement by visual inspection.
^ After installing the bolts, make sure that crankshaft can be rotated smoothly by hand.
^ Wipe off completely any protruding liquid gasket on front side of the engine.
^ Check the crankshaft end play. Refer to "CRANKSHAFT END PLAY".
8. Inspect the outer diameter of connecting rod bolt. Refer to "CONNECTING ROD BOLT OUTER DIAMETER".
9. Install piston to connecting rod as follows:
a. Install new snap ring to the groove of piston rear side using suitable tool. * Insert it fully into groove to install.
b. Install piston to connecting rod.
^ Using industrial use drier 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.
c. Install new snap ring to the groove of the piston front side.
^ Insert it fully into groove to install.
^ After installing, make sure that connecting rod moves smoothly.
10. Install piston rings using piston ring expander or suitable tool.
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.
NOTE: If there is no stamp on ring, no specific orientation is required for installation.
Stamped mark:
Top ring: -
Second ring: R
^ Position each ring with the gap as shown referring to the piston front mark.
^ Check the piston ring side clearance. Refer to "PISTON RING SIDE CLEARANCE".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
^ 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 with cutout of connecting rods and connecting rod bearing caps to install.
^ Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft.
13. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
14. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
15. Match the cylinder position with the cylinder number on connecting rod to install.
NOTE: Be sure that front mark on piston head is facing front of engine.
16. Install piston with the front mark on the piston head facing the front of engine using Tool.
Tool number: EM03470000 (J-8037)
CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
17. 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 on connecting rod bearing cap is facing front of engine.
18. Tighten connecting rod bolts as follows:
a. Apply engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts.
Connecting rod bolt: 19.6 Nm (2.0 kg-m, 14 ft. lbs.)
c. Then tighten all connecting rod bolts 90° clockwise.
CAUTION: Always use Tool. Avoid tightening based on visual check alone.
Tool number: KV10112100 (BT-8653-A)
^ After tightening connecting rod bolts, make sure that crankshaft rotates smoothly
^ Check the connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE".
19. Install pilot converter (A/T models).
^ With drift of the following outer diameter, press-fit as far as it will go.
Pilot converter: Approximately 33 mm (1.30 inch)
^ Press-fit pilot converter with its chamfer facing crankshaft as shown. (A/T models)
20. Install knock sensors.
^ Install knock sensor so that connector faces rear of engine.
^ After installing knock sensor, connect harness connector, and lay it out to rear of engine.
CAUTION:
^ Do not tighten bolts while holding connector.
^ If any impact by dropping is applied to knock sensor, replace it with new one.
NOTE:
^ Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
^ Make sure that knock sensor does not interfere with other parts.
21. Assemble in the reverse order of disassembly after this step.
Drive plate (A/T models)
^ Install drive plate and reinforcement plate as shown.
^ Holding ring gear using Tool.
Tool number: KV10117700 (J-44716)
^ Tighten bolts crosswise over several times.