Disassembly And Assembly
ENGINE UNIT
Disassembly and Assembly
DISASSEMBLY
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, some steps may be different.
1. Remove engine assembly and mount to engine stand. Removal And Installation.
CAUTION:
Before removing the hanging chains, make sure engine stand is stable and there is no risk of overturning.
2. Drain engine oil. Removal and Replacement.
3. Drain engine coolant by removing the cylinder block drain plugs "A", "B", "C" and "D" as shown.
4. Remove the following components and associated parts (the parts referred to in step 1 are not included here).
- Oil pan (upper and lower) and oil strainer. Removal and Installation.
- Crankshaft pulley, front cover and timing chain. Removal And Installation.
- Camshaft. Removal And Installation.
- Cylinder head. Removal And Installation.
5. Remove knock sensor and sub harness.
CAUTION:
Carefully handle sensor, avoiding shocks.
6. Check connecting rod side clearance. Inspection After Disassembly.
7. Remove piston and connecting rod assembly as follows.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center.
b. Remove connecting rod cap.
c. Push the piston and connecting rod assembly out to the cylinder head side using suitable tool.
8. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
9. Check piston ring side clearance. Inspection After Disassembly.
10. Remove piston rings from piston using suitable tool.
CAUTION:
- Do not damage piston.
- Do not damage piston rings by expanding them excessively.
11. Remove piston from connecting rod as follows.
a. Remove snap ring using suitable tool.
b. Heat piston to 60� to 70�C (140� to 158�F) using suitable tool.
c. Push out piston pin using suitable tool.
12. Separate and remove rear oil seal retainer from cylinder block.
CAUTION:
Do not damage mating surface.
13. Remove rear oil seal from rear oil seal retainer.
14. Measure the crankshaft side clearance. Inspection After Disassembly.
15. Remove main bearing caps as follows:
- Loosen bolts in several different steps.
a. Loosen side bolts (M10) starting from 30 to 21 to remove.
b. Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to remove.
c. Loosen main bearing cap bolts (M12) starting from 10 to 1 to remove.
d. Remove main bearing cap.
- Insert bolts (2) into bolt holes, and then remove main bearing cap by lifting up and shaking forward and backward.
16. Remove crankshaft.
17. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.
- When removing them, note the installation position. Keep them in the correct order.
18. Remove pilot converter using Tool if necessary.
Tool number : ST16610001 (J-23907)
ASSEMBLY
1. Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove any foreign material.
WARNING:
Use goggles to protect your eyes.
2. Install each plug to the cylinder block (only screw-type plugs are shown).
- Apply liquid gasket.
Use Genuine Thread Sealant or equivalent. Fluid Type Specifications.
- Replace copper washers with new ones.
- Tighten each plug as specified below.
3. Install main bearings and thrust bearings.
a. Remove any dust, dirt, and oil on the bearing mating surfaces of the cylinder block and main bearing caps.
b. Install thrust bearings to both sides of the No. 3 journal housing on the cylinder block and main bearing caps
- Install thrust bearings with the oil groove facing the crankshaft arm (outside).
- Install thrust bearings with a protrusion in the center on the main bearing caps.
c. Install main bearings paying attention to the direction.
- Install the one with oil holes onto the cylinder block and the one without oil holes onto the main bearing cap.
- Before installing bearings, apply engine oil to bearing surface
(inside). Do not apply oil to the back surface, but thoroughly clean it.
- When installing, align the bearing stopper to the notch.
- Ensure the oil holes on the cylinder block and those on the corresponding bearing are aligned.
4. Install pilot converter to the crankshaft using suitable tool.
5. Install crankshaft to the cylinder block.
- While turning crankshaft by hand, make sure it turns smoothly.
6. Install main bearing caps.
- Align the identification number to the journal position to install.
- Install it with the front mark (indicated by the arrow) facing the front of engine.
- Tap caps lightly to seat them in the installation position.
7. Follow the steps below to tighten each main bearing cap bolt.
a. Apply engine oil to threads and seating surfaces of bolts, and tighten all bolts temporarily.
b. Measure tightening angle using Tool.
Tool number : KV10112100 (BT-8653-A)
CAUTION:
Measure tightening angle using Tool. Do not measure visually.
- Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
- Check crankshaft side clearance. Inspection After Disassembly.
8. Install rear oil seal to rear oil seal retainer.
CAUTION:
Do not damage or scratch outer circumference of oil seal.
- Install new rear oil seal in the direction shown.
- Tap until flattened with the front edge of the rear oil seal retainer using suitable tool.
- Fit the rear oil seal until it is level with the rear end surface of rear oil seal retainer.
9. Install rear oil seal retainer.
- Apply liquid gasket thoroughly to rear oil seal retainer as shown.
Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.
- Apply new engine oil on the lips of rear oil seal. Do not touch.
10. Install the piston to the connecting rod.
a. Install the snap ring to the grooves of the piston rear side.
- Insert it fully into the groove to install.
b. Install the piston to the connecting rod.
- Heat piston until piston pin can be pushed in by hand without excess force [approx. 60� to 70 C� (140� to 158 �F)]. From the front to the rear, insert the piston pin into the piston and the connecting rod.
- Assemble so that the front mark on the piston crown and the oil holes and cylinder No. on the connecting rod are positioned as shown.
c. Install the snap ring to the grooves of the piston front side.
- Insert it fully into the groove to install.
- After installing, make sure connecting rod moves smoothly.
11. Install piston rings.
CAUTION:
Do not damage piston.
- Position each ring with the gap as shown, referring to the piston front mark.
- Install the second ring with the stamped surface facing upward.
Stamped mark Second ring : 2N
12. Install the connecting rod bearings to the connecting rod and connecting rod cap.
- When installing the connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
- When installing, align the connecting rod bearing stopper protrusion with the cutout of the connecting rod to install.
- Check that the oil holes on the connecting rod and those on the corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft using Tool.
Tool number : EM03470000 (J-8037)
- Position the crankshaft pin corresponding to the connecting rod to be installed onto bottom dead center.
- Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
- Match the cylinder position with the cylinder No. on the connecting rod to install.
- Install the piston with the front mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from an interference of the connecting rod big end.
14. Install connecting rod cap.
- Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap to install.
15. Tighten connecting rod bolts using Tool.
- Apply engine oil to threads and seats of connecting rod bolts.
- After tightening bolts, make sure the crankshaft rotates smoothly.
- Check connecting rod side clearance. Inspection After Disassembly.
16. Install knock sensors.
CAUTION:
If knock sensor is dropped, replace it with a new one.
- Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
- Install it with its connector facing the center of the cylinder block side.
- Do not tighten knock sensor bolts while holding connector.
- Make sure knock sensor does not interfere with other parts.
- Position the sub-harness as shown before installing intake manifold.
17. Installation of the remaining components is in the reverse order of removal.
18. Remove engine assembly from engine stand.
19. Install drive plate.
- Align dowel pin of crankshaft rear end with pin holes of each part to install.
- Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown.
- Face the chamfered or rounded edge side to the crankshaft.