Disassembly

COMPONENTS FOR CYLINDER BLOCK DISASSEMBLY
PREPARATION FOR DISASSEMBLY
1. REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.
2. REMOVE REAR END PLATE
Remove the bolt and end plate.
3. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY






4. REMOVE OIL LEVEL SENSOR WIRE
(a) Disconnect the 2 connectors.
(b) Remove the 2 bolts and sensor wire.
5. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and mounting bracket.
6. REMOVE ALTERNATOR






7. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION: Turn the ignition switch to "LOCK". Disconnect the negative terminal cable from the battery. With at least 20 seconds before proceeding with work.
8. REMOVE DRIVE BELT











(a) Loosen the pivot bolt and adjusting lock bolt.
(b) Loosen the adjusting bolt, and disconnect the drive belt from the alternator.
9. REMOVE ALTERNATOR
(a) Disconnect the alternator connector.
(b) Remove the nut, and disconnect the alternator wire.
(c) Remove the pivot bolt, adjusting lock bolt and alternator.
10. REMOVE ALTERNATOR BRACKET
Remove the 3 bolts, 2 nuts and generator bracket.
11. REMOVE TIMING BELT AND PULLEYS






TIMING BELT COMPONENTS
REMOVAL OF TIMING BELT
1. Remove engine under covers.
2. Remove RH engine hood side panel.
3. Remove suspension upper brace.
4. (w/Cruise control system) Remove cruise control actuator and accelerator linkage.
5. Remove intercooler.
6. Remove RH rear wheel.






7. Slightly jack up engine.






Raise the engine enough to remove the weight from the engine mounting on the right side.

8.. Remove RH engine mounting stay.






Remove the two bolts, nut and mounting stay.

9. Remove RH engine mounting insulator.






Remove the through bolt, two nuts and mounting insulator.

10. Remove RH engine mounting bracket.






Remove the three bolts and mounting bracket.

HINT: Raise the jack and perform the operation with the engine fully up.

11. Remove EGR vacuum modulator and VSV.
12. Remove throttle body.
13. Remove hose clamp and VTV clamp off air by-pass valve.
14. Remove cylinder head cover.
15. Remove spark plugs.
16. Remove No. 2 timing belt cover.






Remove the five screws, timing belt cover and gasket.

17. Set cylinder to TDC/compression.






(a) Turn the crankshaft pulley and align its groove with timing mark "0" of the No. 1 timing belt cover.

NOTICE: Always turn the crankshaft clockwise.






(b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No. 3 timing belt cover. If not, turn the crankshaft one revolution (360°).
18. Remove timing belt from camshaft timing pulleys.






HINT:
- (Re-using timing belt)
Place matchmarks on the timing belt and camshaft timing pulleys and place a matchmark on the timing belt to match the end of the No. 1 timing belt cover.






- Place matchmarks on the timing belt and RH camshaft timing pulley . To prevent losing the proper meshing of the timing belt with the pulley tie a siring as shown.






(a) Remove the two bolts and timing belt tensioner.






(b) Remove the timing belt from the camshaft timing pulley.
19. Remove camshaft timing pulleys.






(a) Hold the hexagonal wrench head portion of the camshaft with a wrench and remove the pulley mount bolts.

HINT: (Intake camshaft timing pulley): Use SST 09249-63010.

(b) Remove the camshaft pulleys and pins.

HINT: Arrange the intake and exhaust timing pulleys.

20. Remove crankshaft pulley.






(a) Using SST 09213-54015 (90119-08216) and 09330-00021, remove the pulley bolt.






HINT: (When re-using timing belt): After loosening the crankshaft pulley bolt, check that the timing belt matchmark aligns with the end of the No.1 timing belt cover when the crankshaft pulley groove is aligned with the timing mark "0" of the No. 1 timing belt cover. If the matchmark does not align, align as follows:






(When matchmark is out of alignment clockwise)
- Align the matchmark by pulling the timing belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise.






- After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley clockwise, and align its groove with timing mark "0" of the No. l timing belt cover.






(When matchmark is out of alignment counterclockwise)
- Align the matchmark by pulling the timing belt up on the No. 1 idler pulley side while turning the crankshaft pulley clockwise.






- After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley counterclockwise, and align its groove with timing mark "0" of the No. 1 timing belt cover.






(b) Using SST 09213-31021, remove the pulley.

HINT: (When re-using timing belt): Remove the pulley without turning it.

21. Remove No. 1 timing belt cover.






Remove the six bolts, timing belt cover and gasket.






22. Remove timing belt guide.
23. Remove timing belt.






HINT: (When re-using timing belt): Draw an arrow on the timing belt (in the direction of engine revolution) and place matchmarks on the timing belt and crankshaft timing pulley.

24. Remove No.1 idler pulley.






Remove the pivot bolt, pulley and plate washer.

25. Remove No. 2 idler pulley.






Remove the bolt and pulley.

26. Remove crankshaft timing pulley.






If the pulley cannot be removed by hand, use two screwdrivers.

HINT: Position shop rags as shown to prevent damage.

27. Remove oil pump pulley.






Using SST 09616-30011, remove the nut and pulley.
28. REMOVE CYLINDER HEAD Cylinder Head Assembly
29. REMOVE OIL PAN AND OIL PUMP
30. REMOVE OIL DIPSTICK GUIDE
Remove the bolt, and pull out the dipstick guide.






31. REMOVE WATER PUMP
(a) w/o A/C:
Remove the bolt (A).
(b) Remove the 3 bolts in the sequence shown.
32. REMOVE OIL COOLER BRACKET



33. REMOVE KNOCK SENSOR Using SST, remove the knock sensor. SST 09816-30010
CYLINDER BLOCK DISASSEMBLY






1. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts, retainer and gasket.






2. CHECK CONNECTING ROD THRUST CLEARANCE
sing a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 - 0.312 mm (0.0063 - 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE






(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.






(b) Remove the 2 connecting rod cap nuts.
(c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.
HINT: Keep the lower bearing inserted with the connecting cap.






(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.






(g) Lay a strip of Plastigage across the crank pin.






(h) Install the connecting rod cap. (See step 6 in cylinder block assembly in Engine mechanical)
Torque: 67 N.m (680 kgf.cm, 49 ft. Ibf)

NOTICE: Do not turn the crankshaft.

(i) Remove the connecting rod cap. (See procedure (b) and (c) above)






(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD 0.024 - 0.055 mm (0.0009 - 0.0022 in.)
U/S 0.25 0.023 - 0.069 mm (0.0009 - 0.0027 in.)
Maximum oil clearance: 08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crank- shaft.






HINT: If using a standard bearing. replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked "1", "2"and "3"accordingly.
Standard sized bearing center wall thickness:
Mark "1" 1.484 - 1.488 mm (0.0584 - 0.0586 in.)
Mark "2" 1.488 - 1.492 mm (0.0586 - 0.0587 in.)
Mark "3" 1.492 - 1.496 mm (0.0587 - 0.0589 in.)
(k) Completely remove the Plastigage.
4. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES






(a) Using a ridge reamer. remove all the carbon from the top of the cylinder.






(b) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.






5. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 in.)






6. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown.






(b) Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearing and 2 lower thrust washers (No.3 main bearing cap only).

HINT:
- Keep the lower bearing and main bearing cap together.
- Arrange the main bearing caps and lower thrust washers in the correct order.
(c) Lift out the crankshaft.

HINT: Keep the upper bearing and upper thrust washers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.






(g) Lay a strip of Plastigage across each journal.






(h) Install the main bearing caps. (See step 5 in cylinder block assembly in Engine Mechanical)
Torque: 59 N.m (600 kgf.cm, 43 ft. lbf)

NOTICE: Do not turn the crankshaft.

(i) Remove the main bearing caps. (See procedure (a) and (b) above)






(j) Measure the Plastigage at its widest point.
Standard clearance: No.3
STD 0.025 - 0.044 mm (0.0010 - 0.0017 in.)
U/S 0.25 0.021 - 0.061 mm (0.0008 - 0.0024 in.)
Others
STD 0.015 - 0.034 mm (0.0006 - 0.0013 in.)
U/S 0.25 0.029 - 0.069 mm (0.0011 - 0.0027 in.)
Maximum clearance: 0.08 mm (0.0031 in.)






HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be:
No.3 0.027 - 0.054 mm (0.0011 - 0.0021 in.)
Others 0.017 - 0.044 mm (0.0007 - 0.0017 in.)
If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.






HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.
Reference:






(k) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper bearings and 2 upper thrust washers from the cylinder block.






8. REMOVE OIL NOZZLES
Using a 5 mm hexagon wrench, remove the bolt and oil nozzle. Remove the 4 oil nozzles.