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Disassembly and Assembly
 
 
DISASSEMBLY
 
 
1. Mount the engine on a suitable engine stand. Refer to Setting.Setting
2. Drain any remaining engine oil and engine coolant if necessary.
3. Remove drain plugs from cylinder block.
4. Remove cylinder head. Refer to Removal and Installation.Removal and Installation
5. Remove oil pan (upper). Refer to Removal and Installation.Removal and Installation
6. Remove the thermostat housing. Refer to Removal and Installation.Removal and Installation
7. Remove knock sensors.
cautionCarefully handle knock sensor avoiding shocks.
8. Remove crankshaft position sensor.
caution
  • Avoid impacts such as dropping.
  • Do not disassemble.
  • Keep crankshaft position sensor away from metal particles.
  • Do not place crankshaft position sensor in a location where it is exposed to magnetism.
9. Remove piston and connecting rod assembly with the following procedure:
  • Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to Inspection.
(1) Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
(2) Remove connecting rod cap. Number connecting rod caps so they can be assembled in the same position and direction.
(3) Using a suitable tool, push piston and connecting rod assembly out to cylinder head side.
caution
  • Do not damage matching surface with connecting rod cap.
  • Do not damage cylinder wall and crankshaft pin when removing piston and connecting rod assembly.
noteNumber the pistons and rods so they can be installed in the same position.
10. Remove connecting rod bearings.
cautionWhen removing them note the installation position. Keep them in the correct order.
11. Remove piston rings from piston.
  • Before removing piston rings check the piston ring side clearance. Refer to Inspection.
  • Remove piston rings using suitable tool (A).
    caution
    • When removing piston rings, do not damage the piston.
    • Do not damage piston rings by expanding them excessively.
12. Remove piston from connecting rod using the following procedure:
(1) Remove snap rings using snap ring pliers (A).
(2) Heat piston to 60°C to 70°C (140°F to 158°F) with a suitable tool (A).
(3) Push out piston pin using a suitable tool.
13. Remove ladder assembly using the following procedure:
  • Measure crankshaft end play before loosening ladder assembly bolts. Refer to Inspection.
(1) Loosen and remove ladder assembly bolts in reverse of the sequence shown.
: Engine front
(2) Remove the ladder assembly using seal cutter [KV10111100 (J-37228)] (A).
cautionDo not damage the mating surfaces.
noteIn areas where the cutter is difficult to use, use a plastic hammer to lightly tap the cutter where the liquid gasket is applied. Use a plastic hammer to slide the cutter by tapping on the side.
(3) Remove the ladder assembly while tapping lightly with a plastic hammer.
14. Remove crankshaft .
caution
  • Do not damage or deform signal plate mounted on crankshaft.
  • When setting crankshaft on a flat floor surface, use a block of wood to avoid contact between signal plate and floor surface.
  • Do not remove signal plate unless it is necessary.
noteWhen removing or installing signal plate, use socket (size T30).
15. Remove main bearing (upper and lower) and thrust bearings from cylinder block and ladder assembly.
cautionWhen removing bearings note the installation position. Keep them in the correct order.
noteWhen removing the rear oil seal without removing the cylinder block, use a suitable tool to pull it out between the crankshaft and block.
16. Remove oil jets from cylinder block (if necessary).
cautionWhen removing oil jet assemblies note the installation position. Keep them in the correct order.
: Engine front
17. Inspect dowel pins, welch plugs and threaded plugs and remove if necessary.
 
 
ASSEMBLY
 
 
1. Thoroughly clean engine coolant and oil passages in cylinder block, as well as inside of crankcase and cylinder bores, with compressed air.
cautionBe sure to wear protective goggles for protection from flying substances.
2. Install drain plug to cylinder block as shown.
  • Apply liquid gasket to the threads of drain plug .
    Use Genuine RTV Silicone Sealant or an equivalent. Refer to Recommended Chemical Products and SealantsRecommended Chemical Products and Sealants.
    Water drain plug: 9.8 N·m (1.0 kg-m, 87 in-lb)
3. Install oil jets .
: Engine front
4. Install main bearings and thrust bearings using following procedure:
(1) Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and ladder assembly.
(2) Install thrust bearings to both sides of the No. 3 journal housing on cylinder block.
: Engine front
  • Install thrust bearings with the oil groove facing crankshaft arm (outside).
(3) Install the main bearings paying attention to the direction.
  • Before installing bearing, lubricate bearing surface (inside) with clean engine oil.
    cautionDo not apply engine oil to back surface of main bearings.
  • Check that the oil hole in cylinder block and the oil hole in main bearing are aligned. The main bearing without an oil hole goes in ladder assembly.
  • When installing, align main bearing stopper to the notch.
  • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install signal plate to crankshaft (if removed).
(1) Set the signal plate with flange facing toward the counterweight side (engine front side).
(2) After positioning crankshaft and signal plate with positioning dowel pin , tighten bolts.
(3) Remove dowel pin.
cautionBe sure to remove dowel pin.
6. Install crankshaft to cylinder block.
  • While turning crankshaft by hand, check that it turns smoothly.
cautionDo not install rear oil seal yet.
7. Install ladder assembly with the following procedure:
noteLadder assembly cannot be replaced as a single part because it is machined together with cylinder block.
(1) Apply a bead of liquid gasket with a suitable tool to ladder assembly as shown.
noteAfter tightening ladder assembly, remove liquid gasket that protrudes at location () shown.
: Cylinder block
: Apply liquid gasket to end
B: View B
D: 1.5 mm (0.059 in)
E: 3.4 - 4.4 mm (0.134 - 0.173 in)
: Engine outside
Use Genuine RTV Silicone Sealant or equivalent. Refer toRecommended Chemical Products and SealantsRecommended Chemical Products and Sealants.
(2) Apply new engine oil to threads and seat surfaces of the bolts.
(3) Tighten ladder assembly bolts to specified torque in the sequence shown.
Step 1Bolts 1 – 10: 39.2 N·m (4.0 kg-m, 29 ft-lb)
Step 2Bolts 11 – 22: 25.1 N·m (2.6 kg-m, 19 ft-lb)
: Engine front
(4) Tighten bolts to specified in the sequence shown using angle wrench [KV10112100 (BT-8653-A)] (A).
cautionCheck tightening angle. Do not judge angle by visual inspection.
Bolts 1 – 22: 60° – 65°
(5) Install rear oil seal. Refer to Removal and Installation.Removal and Installation
8. Install piston to connecting rod with the following procedure:
(1) Install new snap ring to the groove of the piston rear side using snap ring pliers.
  • Insert it fully into groove to install.
cautionDo not reuse snap rings.
(2) Assemble piston to connecting rod.
  • Using a heat gun (A), heat piston until piston pin can be pushed in by hand without excess force [approximately 60°C to 70°C (140°F to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod.
  • Set so that the front mark on the piston head, the oil splash and the cylinder number on connecting rod are positioned as shown.
(3) 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.
9. Install piston rings using suitable tool.
  • Position each ring with the gap as shown referring to the piston front mark .
    : Oil ring upper or lower rail gap (either of them)
    : Second ring and oil ring spacer gap
    : Top ring gap
  • Install second ring with the stamped surface facing upward.
caution
  • Do not damage piston.
  • Do not damage piston rings by expanding them excessively.
  • Do not contact rail end gap under oil ring with oil drain cast groove of piston.
10. Install connecting rod bearings to connecting rod and connecting rod cap.
  • When installing connecting rod bearings apply new engine oil to the bearing surface (inside).
    cautionDo not apply engine oil to the back surface of connecting rod bearings.
  • When installing, align the connecting rod bearing stopper protrusion with the cutout of connecting rod and connecting rod cap to install.
  • Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
11. Install piston and connecting rod assembly to crankshaft.
  • Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
  • Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
  • Match the cylinder position with the cylinder number on connecting rod to install.
  • Using a suitable tool (A), install piston with the front mark on the piston head facing the front of the engine.
    cautionDo not damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
12. Install connecting rod cap.
  • Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.
    : Oil splash
    : Small end diameter grade
    : Production control number
    : Bearing stopper groove
    : Production control number
    : Cylinder number
    : Big end diameter grade
13. Tighten connecting rod bolts using angle wrench [KV10112100 (BT-8653-A)] (A) with the following procedure:
(1) Apply engine oil to the threads and seats of the connecting rod bolts.
(2) Tighten connecting rod cap bolts to the specified torque.
Step 1: Tighten 27.4 N·m (2.8 kg-m, 20 ft-lb)
Step 2: Loosen 0 N·m
Step 3: 19.6 N·m (2.0 kg-m, 14 lb-ft)
(3) Tighten connecting rod cap bolts to the specified angle.
cautionCheck tightening angle. Do not judge angle by visual inspection.
Bolts: Tighten 90° - 95°
(4) After tightening connecting rod bolts, check that crankshaft rotates smoothly.
(5) Check the connecting rod side clearance. Refer to Inspection.
14. Install knock sensors .
  • Install knock sensor with connector facing +/- 15° as shown.
caution
  • Do not tighten bolts while holding connector.
  • If any impact by dropping is applied to knock sensor, replace it with a 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.
15. Install crankshaft position sensor (POS).
cautionDo not reuse O-ring.
16. Assembly of remaining components is in the reverse order of disassembly.
If replacing or removing piston, connecting rod or crankshaft perform "Electric intake valve timing control actuator position learning". Refer to Work Procedure.