Disassembly and Assembly
CYLINDER BLOCK
Disassembly and Assembly
DISASSEMBLY
1. Remove engine assembly from vehicle, and separate front suspension member and transmission from engine. (2WD models) or (AWD models).
2. Remove engine mounting brackets (RH and LH). (2WD models) or (AWD models).
3. Remove the parts that may restrict installation of engine to widely use engine stand.
NOTE:
The procedure is described assuming that you use a widely use engine stand holding the surface, to which transmission is installed.
- Remove drive plate. Fix crankshaft with a ring gear stopper [SST: KV10118600 (J-48641)], and remove mounting bolts.
- Loosen mounting bolts in diagonal order.
- Check for deformation or damage.
CAUTION:
- Never disassemble drive plate.
- Never place drive plate 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.
4. Remove pilot converter using pilot bushing puller [SST:
ST16610001 (J23907)] (A) or suitable tool if necessary.
5. Lift the engine with hoist to install it onto the widely use engine stand.
- A widely use engine stand (A) can be used.
CAUTION:
Use engine stand that has a load capacity [approximately
220 kg (485 lb) or more] large enough for supporting the engine weight.
NOTE:
This example is engine stand for holding at transmission mounting side with drive plate removed.
6. Drain engine oil. Removal and Replacement.
7. Drain engine coolant by removing water drain plugs (1) from cylinder block both sides as shown in the figure.
2: Washer
3: Plug
4: Plug
White arrow: Engine front
8. Remove oil pan (upper and lower). Component Removal and Installation.
9. Remove front timing chain case, timing chain and rear timing chain case. Removal and Installation.
10. Remove cylinder head. Component.
11. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
12. Remove rear oil seal.
13. Remove baffle plate from lower cylinder block.
14. Remove piston and connecting rod assembly as follows:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Inspection After Disassembly.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
15. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
Identify installation position, and store them without mixing them up.
16. Remove piston rings form piston.
- Before removing piston rings, check the piston ring side clearance. Inspection After Disassembly.
- Use piston ring expander (commercial service tool) (A).
CAUTION:
- When removing piston rings, be careful not to damage piston.
- Be careful not to damage piston rings by expanding them excessively.
17. Remove piston from connecting rod as follows:
a. Using snap ring pliers (A), remove snap ring.
Heat piston to 60 to 70�C (140 to 158�F) with industrial use drier b.
(A) or equivalent.
c. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 in).
18. Remove lower cylinder block bolts.
NOTE:
Use TORX socket (size E14).
- Before loosening lower cylinder block bolts, measure the crankshaft end play. Inspection After Disassembly.
- Loosen lower cylinder block bolts in reverse order shown in the figure in several different steps.
White arrow: Engine front
19. Remove lower cylinder block as follows:
Screw M8 bolt [Pitch: 1.25 mm (0.0492 in), Length: approximately 50 mm (1.97 in)] into bolt holes (A) shown in the figure.
Then equally tighten each bolt, and remove lower cylinder block.
White arrow: Engine front
CAUTION:
- Be careful not to damage the mating surface.
- Never tighten bolts too much.
- Never insert screw driver, this will damage the mating surface.
20. Remove crankshaft.
21. Pull rear oil seal out from rear end of crankshaft.
22. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
- Identify installation positions, and store them without mixing them up.
- Be careful not to drop main bearing, and to scratch the surface.
23. 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 in the figure.
White arrow: Engine front
- Apply sealant to the thread of water drain plug (1).
Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.
- Apply sealant to the thread of plugs (3) and (4).
Use genuine high strength thread locking sealant or equivalent. Fluid Type Specifications.
- Replace washers (2) with new one.
- Tighten each plug as specified below.
3. Install oil jet.
- Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
White arrow: Engine front
4. Install main bearings and thrust bearings as follows:
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
b. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block.
- Install thrust bearings (1) with the oil groove (E) facing crankshaft arm (outside).
A: No. 1
B: No. 2
C: No. 3
D: No. 4
F: Thrust bearing installation position
White arrow: Engine front
- Install thrust bearing with a protrusion on one end on cylinder block. Align each protrusion with mating notch.
c. Install main bearings paying attention to the direction.
A: Cylinder block side
D: Lower cylinder block side
White arrow: Engine front
- Main bearing with oil hole (B) and groove (C) 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. Install lower cylinder block.
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.
- Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to lower cylinder block as shown in the figure.
B: Apply to end
a: [diameter]4.0 - 5.0 mm (0.157 - 0.197 in) dia
Use genuine high strength thread locking sealant or equivalent. Fluid Type Specifications.
7. Inspect the outer diameter of lower cylinder block bolt. Inspection After Disassembly.
8. Install lower cylinder block bolts in numerical order as shown in the figure as follows:
a. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
b. Tighten lower cylinder block bolt (No. 17 to 26) in numerical order as shown in the figure.
White arrow: Engine front
Torque: 25.0 Nm (2.6 kg-m, 18 ft-lb)
c. Repeat step b.
d. Tighten lower cylinder block bolts (No. 1 to 16) in numerical order as shown in the figure.
White arrow: Engine front
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16.
Torque : 35.3 Nm (3.6 kg-m, 26 ft-lb)
e. Turn lower cylinder block bolts (No. 1 to 16) 90 degrees clockwise (angle tightening).
CAUTION:
Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
- After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.
- Check the crankshaft end play. Inspection After Disassembly.
9. Install piston to connecting rod as follows:
a. Using snap ring pliers, install new snap ring to the groove of piston rear side.
- 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 in the figure.
A: Piston grade number
B: Front mark
C: Pin grade number
D: Cylinder number
E: Front mark
White arrow: Engine front
c. Install new snap ring to the groove of the piston front side.
- Insert it fully into groove to install.
- After installing, check that connecting rod moves smoothly.
10. Using piston ring expander (commercial service tool) (A), install piston rings.
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.
Stamped mark:
Top ring (A): 1 N
Second ring (B): 2 N
- Mount second ring with cut out side down.
- Position each ring with the gap as shown in the figure referring to the piston front mark (D).
C: Top ring gap
E: Oil ring upper or lower rail gap
F: Second ring and oil ring spacer gap
a: 90 degrees
b: 45 degrees
- Check the piston ring side clearance. Inspection After Disassembly.
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 (B) with cutout (C) of connecting rods and connecting rod bearing caps to install.
- Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft.
- Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
- Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
- Match the cylinder position with the cylinder number on connecting rod to install.
- Be sure that front mark on piston head is facing front of engine.
- Using piston ring compressor [SST: EM03470000 (J8037)] (A) or suitable tool, install piston with the front mark on the piston head facing the front of engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
13. 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 (H) on connecting rod bearing cap is facing front of engine.
A: Sample code
B: Bearing stopper groove
C: Small-end [diameter]grade
D: Big end [diameter]grade
E: Weight grade
F: Cylinder No.
G: Management code
I: Management code
14. Inspect the outer diameter of connecting rod bolt. Inspection After Disassembly.
15. Tighten connecting rod bolts as follows:
a. Apply engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts.
Torque: 28.4 Nm (2.9 kg-m, 21 ft-lb)
c. Completely loosen connecting rod bolts.
Torque: 0 Nm (0 kg-m, 0 ft-lb)
d. Tighten connecting rod bolts.
Torque: 24.5 Nm (2.5 kg-m, 18 ft-lb)
e. Then turn connecting rod bolts 90 degrees clockwise (angle tightening).
CAUTION:
Use angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
- After tightening connecting rod bolts, check that crankshaft rotates smoothly.
- Check the connecting rod side clearance. Inspection After Disassembly.
16. Install baffle plate.
17. Install new rear oil seal. Service and Repair.
18. Install pilot converter.
- With drift of the following outer diameter, press-fit as far as it will go.
Pilot converter: Approximately 33 mm (1.30 in)
- Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure.
White arrow: Crankshaft side
19. Install cylinder head. Component.
20. Install rear timing chain case. Removal and Installation.
21. Install oil pan (upper). Component Removal and Installation.
22. Install knock sensors.
A: Bank 1
B: Bank 2
White arrow: Engine front
- 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:
- Never tighten mounting bolts while holding connector.
- If any impact by dropping is applied to knock sensor, replace it with 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.
23. Note the following, assemble in the reverse order of disassembly after this step.
Drive plate
- When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
CAUTION:
If these are not aligned correctly, engine runs roughly and "MIL" turns on.
- Install drive plate (2) and reinforcement plate (3) as shown in the figure.
1: Ring gear
4: Pilot converter
5: Crankshaft
A: Rounded
White arrow: Engine front
- Holding ring gear with ring gear stopper [SST: KV10118600 (J-48641)].
- Tighten the mounting bolts crosswise over several times.