Disassembly

CYLINDER BLOCK:

DISASSEMBLY

CAUTION: Apply new engine oil to parts marked in illustration before installation.

NOTE: Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, note with difference in steps and etc.

1. Remove engine assembly.
2. Remove the parts that may restrict installation of engine to general-purpose engine stand.

NOTE: The procedure is described assuming that you use a general-purpose engine holding the surface, to which transmission is installed.

a. Remove drive plate.
Holding crankshaft pulley mounting bolts, lock crankshaft to remove bolts fixing drive plate.
Loosen fixing bolts diagonally.


CAUTION :Be careful not to damage drive plate. Especially, avoid deforming and damaging of signal plate teeth (circumference position).
Place the drive plate with signal plate surface facing other than downward.
Keep magnetic materials away from signal plate.

b. Remove engine rear plate.
3. Lift the engine with hoist to install it onto the general-purpose engine stand.

CAUTION: Use an engine stand that has a load capacity large enough for supporting the engine weight.

If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand.
- Remove intake manifold upper and intake manifold lower.
- Remove exhaust manifold and three way catalyst.
- Remove fuel injector and fuel tube.
- Remove starter motor.
- Remove ignition coil.
- Remove rocker cover.
- Other removable brackets.






NOTE: The figure shows an example of general-purpose engine stand that can hold mating surface of transmission with drive plate and rear plate removed.

CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.

4. Drain engine oil and coolant from inside of engine.
5. Remove the following components and associated parts (The parts listed in step 3 are not included here.)
- Oil pan and oil strainer.
- Crankshaft pulley, front cover and timing chain.
- Camshaft.
- Cylinder head.

6. Remove knock sensor.

CAUTION: Carefully handle the sensor, avoiding shocks.

7. Remove the piston and connecting rod assembly.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center.
b. Remove the connecting rod cap.






c. Using a hammer handle or similar tool, push the piston and connecting rod assembly out to the cylinder head side.
Before removing the piston and connecting rod assembly, check the connecting rod side clearance.

8. Remove the connecting rod bearings.

CAUTION: When removing them, note the installation position. Keep them in the correct order.

9. Remove the piston rings form the piston.






Use a piston ring expander.

CAUTIO N:When removing the piston rings, be careful not to damage the piston.
Be careful not to damage piston rings by expanding them excessively.

Before removing the piston rings, check the piston ring side clearance.

10. Remove the piston from the connecting rod as follows.






a. Using a snap ring pliers, remove the snap ring.






b. Heat piston to 60 to 70°C (140 to 158°F) with drier or equivalent.






c. Push out piston pin with stick of outer diameter approximately 20 mm (0.8 inch).

11. Remove the rear oil seal retainer from the cylinder block.
Insert a minus-head screwdriver or similar tool between the rear end of the crankshaft counter weight and rear oil seal retainer, and separate the liquid gasket to remove.

CAUTION: Be careful not to damage the mating surface.

12. Using a minus-head screwdriver or similar tool, and lever off the rear oil seal from the rear oil seal retainer.
13. Remove the main bearing cap as follows: Before loosening the main bearing cap bolts, measure the crankshaft side clearance.
a. Remove the cover attached to the rear left side of the cylinder block (next to the starter motor housing).






NOTE: Bolts (No. 27 shown in the figure) are installed on the inside of the cover.

b. Loosen the side bolts (M10) starting from 30 to 21 to remove.
c. Loosen the main bearing cap sub bolts (M9) starting from 20 to 11 to remove.
d. Loosen the main bearing cap bolts (M12) starting from 10 to 1 to remove.






e. Using a main bearing cap remover, remove the main bearing cap.

14. Remove the crankshaft.
15. 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.






16. If the pilot converter must be removed, remove it from the rear end of the crankshaft using a pilot bearing puller.
Removal and installation without the engine stand is possible.