Disassembly and Assembly
CYLINDER BLOCK
Disassembly and Assembly
DISASSEMBLY
1. Remove the following parts:
- Oil pans (lower and upper): (2WD models) or Exploded View (AWD models).
- Timing chain: Exploded View.
- Rear timing chain case. Exploded View.
- Cylinder head: Exploded View.
2. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
3. Remove baffle plate from lower cylinder block.
4. Remove piston and connecting rod assembly with the following procedure:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using a 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.
5. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
- Be careful not to drop connecting rod bearing, and to scratch the surface.
- Identify installation positions, and store them without mixing them up.
6. Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Cylinder Block.
- Use a 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.
7. Remove piston from connecting rod as follows:
a. Using a snap ring pliers (A), remove snap rings.
b. Heat piston to 60 to 70�C (140 to 158�F) with an industrial use drier (A) or equivalent.
c. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 in).
8. Remove main bearing cap bolts.
NOTE:
Use TORX socket (size E14).
- Before loosening main bearing cap bolts, measure the crankshaft end play. Inspection.
- Loosen main bearing cap bolts in the reverse order shown in the figure in several different steps.
9. Remove main bearing beam.
10. Remove main bearing caps.
CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
- Using main bearing cap bolts, remove main bearing cap while shaking it back-and-forth.
11. Remove crankshaft.
12. Pull rear oil seal out from rear end of crankshaft.
13. 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.
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.
1 :Drain plug
2 :Drain plug
3 : Plug
4 : Plug
A :Front
B :Right side
C :Left side and back side
White Arrow : Engine front
- Apply liquid gasket to the screw of each plug before tightening.
- Replace washers.
- For gasket name, the presence/absence of washer, and tightening torque, refer to the following list.
- Tighten each plug as specified below.
3. Install main bearings and thrust bearings as follows:
CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
b. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block.
A : No. 1
B : No. 2
C : No. 3
D : No. 4
F : Thrust bearing installation position
White Arrow : Engine front
- Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).
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.
4. Install crankshaft to cylinder block.
- While turning crankshaft by hand, check that it turns smoothly.
5. Install main bearing cap.
- Use a cast-embossed mark to identify main bearing cap. To install main bearing cap, face front mark (E) to the front side.
A : No1
B : No2
C : No3
D : No4
White Arrow : Engine front
NOTE:
Since the main bearing cap is assembled with a cylinder block, always replace as an assembly part.
6. Check outside diameter of the main bearing cap bolt. Inspection
7. Tighten main bearing cap bolt, according to the following procedure.
1. Apply engine oil to the screw and the bearing surface of each bolt.
2. Tighten main bearing cap bolts, according to the numerical order shown in the figure.
White Arrow : Engine front
Tightening torque 35.3N�m (3.6 Kg-m 26ft-lb)
3. Tighten the connecting rod bolt by 90 degrees. (Angular tightening)
CAUTION:
Use angle wrench [SST: KV10112100] (A) for angular tightening. Never judge by visual check.
- After tightening bolts, check that the crankshaft rotates smoothly.
- Check crankshaft side clearance. Inspection
8. Check the outside diameter of connecting rod bolt. Inspection
9. Install piston to connecting rod as follows:
a. Using a 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 an 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 a 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) : R
Second ring (B) : R 2
- 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 (either of them)
F : Second ring and oil ring spacer gap
a : 90 degrees
b : 45 degrees
- Check the piston ring side clearance. Cylinder Block.
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
- 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 crown is facing front of engine.
- Using a piston ring compressor [SST: EM03470000] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the 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.
A : Sample codes
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
- Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
14. Tighten connecting rod bolt as follows:
a. Apply engine oil to the screw and the bearing surface of connecting rod.
b. Tighten the connecting rod bolt to the specified torque.
Tightening torque 19.6Nm (1.9 Kg-m 14ft-lb)
c. Tighten the connecting rod bolt by 90 degrees. (Angular tightening)
CAUTION:
Use angle wrench [SST: KV10112100] (A) for angular tightening. Never judge by visual check.
- After tightening bolts, check that the crankshaft rotates smoothly.
- Check the piston ring side clearance. Inspection, "Inspection".
15. Install rear oil seal retainer.
- Apply liquid gasket (an equivalent of Three Bond 1218B) to the edge shown in the figure in a seamless single layer. Liquid Gasket
a : diameter 2.3-3.3mm (0.091 - 0.130 in)
CAUTION:
Replace rear oil seal retainer with a new one.
NOTE:
Rear oil seal retainer and rear oil seal are assembled parts.
16. Install pilot converter.
- Press pilot converter into the cylinder block all the way to the end with a drift (general purpose tool) measuring approximately 33mm in outside diameter.
NOTE:
The figure shows pilot converter installation as an example.
- Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure.
White Arrow : Crankshaft side
17. Install drive plate as follows:
- Install drive plate and reinforce plate (3) in the direction shown in the figure.
1 : Ring gear
2 : Drive plate
4 : Pilot converter
A : R
White Arrow : Engine front
CAUTION:
Ensure the correct side (front or back) to install.
- To install drive plate and reinforce plate, align the dowel holes with the dowel pins on the rear end of crankshaft (5).
- Fix crankshaft with the ring gear stopper [SST: KV10118700] to tighten the mounting bolt.
- Tighten mounting bolts diagonally in several steps.
18. Install knock sensors.
1 : Knock sensor
White Arrow : Engine front
CAUTION:
- Always use genuine mounting bolts.
- Never hold the connector when tightening the mounting bolts.
- Check that the knock sensor does not interfere with other parts.
- If the knock sensor is physically-impacted, replace it with a new one.
- Check that the cylinder block mounting surface and the knock sensor rear face are free from foreign matter.
- To install the connector, turn it toward the front of the vehicle.
- After installing the knock sensor, connect the sub-harness and set aside its harness cable on the engine rear side.
19. 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 "MI" 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 the ring gear stopper [SST:
KV10118600].
- Tighten the mounting bolts crosswise over several times.