CYLINDER BLOCK

Disassembly and Assembly

• Apply new engine oil to parts as marked in illustrations before installation.
• Place removed parts such as bearings and bearing caps in their proper order and direction.
• When installing the connecting rod nuts, and main bearing cap bolts, apply new engine oil to the threads and mating surfaces
• Do not allow any magnetic materials to contact the signal plate teeth on the drive plate.

DISASSEMBLY

1. Remove the engine assembly. Refer to See: Service and Repair.
2. Install the engine on the engine stand.
3. Remove the knock sensor.

CAUTION:
Carefully handle sensor avoiding shocking it.

4. Drain the engine of all coolant and oil.
5. Remove the oil pan. Refer to See: Oil Pan\Service and Repair.
6. Remove the timing chain. Refer to See: Timing Chain\Service and Repair\Removal and Replacement\Removal.
7. Remove the cylinder head. Refer to See: Cylinder Head Assembly\Service and Repair\Removal and Replacement.
8. Remove drive plate or flywheel. Fix crankshaft with Tool, and remove bolts.

Tool number : KV10117700 (J-44716)

• Loosen bolts in diagonal order.

CAUTION:

• Do not disassemble drive plate.

• Never place the 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.

9. Remove pilot bushing (M/T) or converter (CVT) using Tool.

Tool number : ST16610001 (J-23907)

10. Cut away liquid gasket and remove rear oil seal retainer using Tool. Refer to See: Service Precautions\Precaution For Liquid Gasket.

Tool number : KV10111100 (J-37228)

CAUTION:

• Be careful not to damage mounting surface.
• If rear oil seal retainer is removed, replace it with a new one.

NOTE:
Rear oil seal and retainer form a single part and are handled as an assembly.

11. Remove the piston and connecting rod assemblies.

1. Position the crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center.
2. Remove the connecting rod cap.
3. 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. Refer to See: Specifications\Cylinder Block.

12. Remove the connecting rod bearings.

CAUTION:

• When removing the connecting rod side bearings, note the installation position. Keep them in the correct order.

13. Remove the piston rings from the piston.

• Use a piston ring expander.

CAUTION:

• When removing the piston rings, be careful not to damage the piston. Do not expand the rings excessively.
• Be careful to mark the rings if they are to be reused so they are installed in their original position.
• Before removing the piston rings, check the piston ring side clearance. Refer to See: Inspection.

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

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

CAUTION:
Do not reuse snap rings, always replace with new ones.

2. Heat the pistons to 60° - 70 °C (140° - 158 °F) .
3. Push out the piston pin with a suitable tool, with an outer diameter approximately 20 mm (0.8 in) .

15. Remove the rear oil seal retainer from the cylinder block.

• Insert a 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.

NOTE:
When replacing the rear oil seal during on-vehicle service, it is necessary to remove the oil pan. Refer to See: Oil Pan\Service and Repair.

16. Remove the baffle plate from the main bearing beam.

17. Loosen the bolts in the numerical order as shown and remove the main bearing beam, bearing caps and crankshaft.

• Before loosening the main bearing cap bolts, measure the crankshaft side clearance. Refer to See: Inspection.

18. Remove the oil jets and dowel pins.
19. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.

• When removing them, note the direction and position. Keep them in the correct order for installation.

ASSEMBLY

1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials.

WARNING:
Use goggles to protect your eyes.

2. Apply liquid gasket and install each plug into the cylinder block.

• Use Genuine Silicone RTV Sealant or equivalent. Refer to See: Specifications\Fluid Types.

3. Install the oil jets.

• Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the bolts.

4. Install the main bearings and the thrust bearings.

1. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
2. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.

• Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
• Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.

5. Set the upper main bearings in their proper positions on the cylinder block.

• Confirm the correct main bearings are used. Refer to See: Inspection.

6. Instructions for the re-use of the main bearing cap bolts.

• A plastic zone tightening method is used for tightening the main bearing cap bolts. Measure d1 and d2 as shown.
• For d2, select the minimum diameter in the measuring area.
• If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.

Limit (d1 - d2) : 0.11 mm (0.0043 in)

7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts. Tighten the bearing cap bolts in the numerical order as shown.

1. Make sure that the front marks on the main bearing beam faces the front of the engine.

2. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
3. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
4. Lubricate the threads and seat surfaces of the bolts with new engine oil.
5. Tighten the bolts in two stages:

CAUTION:
Measure the tightening angle in stage 2 using Tool. Do not measure visually.

8. Measure crankshaft end play.

• If beyond the limit, replace the bearing with a new one.

9. Install the rear oil seal retainer.

• Apply sealant to rear oil seal retainer as shown. Use Genuine Silicone RTV Sealant, or equivalent. Refer to See: Specifications\Fluid Types.

10. Install the piston to the connecting rod.

1. Using suitable snap ring pliers, install the snap ring fully into the pin-groove of the piston rear side.

• Piston front mark (A)
• Oil hole (B)
• Connecting rod front mark (C)
• Cylinder No. (D)

2. Install the piston to the connecting rod.

• Heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60° - 70°C (140° to 158°F) ]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.

• Assemble so that the piston front mark (B) on the crown and the oil hole (C), connecting rod front mark (D) and Cylinder No. (E) on the are positioned as shown.
• Arrow indicates Front
• Piston grade number (A)
• Pin grade number (F)

3. Install the snap ring into the front of the piston pin-groove.

• After installing, check that the connecting rod pivots smoothly on the pin.

CAUTION:
Do not reuse snap rings, always replace with new ones.

11. Using a piston ring expander, install the piston rings.

CAUTION:

• Be careful not to damage the piston.
• When the piston rings are not replaced, remount the rings in their original positions.
• When replacing the piston rings, those without stamped surface (A) can be mounted either side up.
• Install the second ring with the stamped surface (B) facing upward. If the ring is not stamped it can face in either direction.

• Position each ring with the gap as shown, referring to the piston front mark.

12. Install the connecting rod bearings to the connecting rod and the connecting rod cap.

• When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it.
• When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install.
• Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.

13. Install the piston and connecting rod assembly into the corresponding cylinder.

• Position the crankshaft pin corresponding to the connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
• Match the cylinder position with the cylinder No. (B) on the connecting rod to install.
• Install the piston with the piston front mark (A) on the crown facing the front of the engine ( ), using a suitable tool.
• Oil hole (C)

CAUTION:
Be careful not to damage the crankshaft pin and cylinder wall, resulting from an interference of the connecting rod big end.

14. Install the connecting rod cap.

• Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
• Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine.
• Lubricate the threads and seat surfaces with new engine oil.

15. Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand.

• Measure the outer diameter of the connecting rod cap bolt as shown.

16. Tighten the connecting rod nuts in two stages using Tool:

• Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
• After tightening the nuts, make sure that the crankshaft rotates smoothly.
• Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft.

17. Install the baffle plate to the main bearing beam.

18. Install the knock sensor.

• Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
• Install the knock sensor with the connector facing the rear of the engine.
• Do not tighten the bolts while holding the connector.
• Make sure that the knock sensor does not interfere with other parts.

CAUTION:
If any impact by dropping occurs to the knock sensor,
replace it with new one.

19. Install the pilot bushing (M/T) or converter (CVT) as shown.
20. Install the flywheel (M/T), if equipped.

• When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.

21. Install the drive plate (CVT), if equipped.

• Install the drive plate and reinforce plate in the direction as shown.
• Align dowel pins of crankshaft rear and drive plate with pin holes of each part.
• Secure the crankshaft using a ring gear stopper.
• Tighten the drive plate bolts in one or two steps.

22. Install the cylinder head. Refer to See: Cylinder Head Assembly\Service and Repair\Removal and Replacement.
23. Install the timing chain. Refer to See: Timing Chain\Service and Repair\Removal and Replacement\Installation.
24. Install the oil pan. Refer to See: Oil Pan\Service and Repair.
25. Remove the engine from the stand and install the engine assembly into the vehicle. Refer to See: Service and Repair.
26. Assembly of the remaining parts is in the reverse order of disassembly.
27. Fill the engine with the specified oil and coolant. Refer to See: Engine Oil and See: Maintenance.

CAUTION:
Wait at least 30 minutes for the sealant to set-up before filling the engine with fluids and running it.