Page 1929 of 2453

ME(H6DO)-63
Cylinder Block
MECHANICAL
16) Remove the bolts which install oil pan upper
onto cylinder block.
NOTE:
Installation bolt has five different sizes. To prevent
the confusion in installation, keep these bolts on
container individually.
17) Remove the service hole cover and service
hole plugs using a hexagon wrench.
18) Rotate the crankshaft to bring #1 and #2 pis-
tons to bottom dead center position, then, using the
ST, remove the piston snap ring through service
hole of #1 and #2 cylinders.
ST 18233AA000 PISTON PIN SNAP RING PLI-
ERS
19) Draw out the piston pin from #1 and #2 pistons
using ST.
ST 499097700 PISTON PIN REMOVER
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.
20) Similarly remove the piston pins from #3, #4,
#5, and #6 pistons.
21) Remove the bolts which secure cylinder block.
22) Separate the cylinder block (LH) and (RH).
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall and damage the cylinder
block.
23) Remove the rear oil seal.
24) Remove the crankshaft together with connect-
ing rod.
25) Remove the crankshaft bearings from cylinder
block using a hammer handle.
NOTE:
•Do not confuse the combination of crankshaft
bearings.
•Press the bearing at the end opposite to locking
lip.
26) Draw out each piston from cylinder block using
wooden bar or hammer handle.
NOTE:
Be careful not to confuse the original combination
of piston and cylinder.
(A) M8 × 40
(B) M8 × 65
(C) M8 × 85
(D) M8 × 130
(E) M8 × 24
ME-02065
(D)(E)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(E)
(A)(A)(A)
(C)(B)
(A)
(D)
(A)
(A)
(A)
(A)
(A)
(B)
ME-00563
ST4
ME-00564
ME-00565
ME-00566
Page 1930 of 2453

ME(H6DO)-64
Cylinder Block
MECHANICAL
B: INSTALLATION
1) After setting the cylinder block to ST, install the
crankshaft bearing.
ST 18232AA000 ENGINE STAND
NOTE:
Remove oil on the mating surface of bearing and
cylinder block before installation. Apply a coat of
engine oil to crankshaft pins.
2) Position the crankshaft and connecting rod on
#2, #4 and #6 cylinder block.
3) Apply liquid gasket to the mating surface of the
#1, #3 and #5 cylinder blocks, and position it on #2,
#4 and #6 cylinder blocks.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007)
NOTE:
Do not allow liquid gasket to run over to O-ring
grooves, oil passages, bearing grooves, etc.
Applying liquid gasket diameter:
1.0±0.2 mm (0.039±0.008 in)
4) Apply a coat of engine oil to the washer and bolt
thread.
5) Tighten all bolts in the numerical order as shown
in the figure.
Tightening torque:
(1) — (11), (13): 25 N·m (2.5 kgf-m, 18 ft-lb)
(12), (14): 20 N·m (2.0 kgf-m, 14 ft-lb)
6) Retighten all bolts in the numerical order as
shown in the figure.
Tightening torque:
(1) — (11), (13): 25 N·m (2.5 kgf-m, 18 ft-lb)
(12), (14): 20 N·m (2.0 kgf-m, 14 ft-lb)
7) Tighten all bolts 90° in the numerical order as
shown in the figure.
8) Install the upper bolt to cylinder block.
Tightening torque:
25 N·m (2.5 kgf-m, 18 ft-lb)
NOTE:
Remove the liquid gasket which is running over to
sealing surface between cylinder block and rear
chain cover, cylinder block and oil pan upper, after
tightening the bolts which combine the cylinder
block.
ME-00567
(1)(6)(8)(3)(9)
(2)(4)(5)(7)(10)
(11)
(12)
(13)
(14)
ME-00568
(1)(6)(8)(3)(9)
(2)(4)(5)(7)(10)
(11)
(12)
(13)
(14)
ME-00568
(1)(6)(8)(3)(9)
(2)(4)(5)(7)(10)
(11)
(12)
(13)
(14)
ME-00568
ME-00569
Page 1931 of 2453

ME(H6DO)-65
Cylinder Block
MECHANICAL
9) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
NOTE:
Apply engine oil to the pressing-in portion.
10) Position the top ring gap at (A) in the figure.
11) Position the second ring gap at (B).
12) Position the upper rail gap at (C) in the figure.
13) Position the expander gap at (D) in the figure.
14) Position the lower rail gap at (E) in the figure.
CAUTION:
•Make sure ring gaps do not face the same di-
rection.
•Make sure ring gaps are not within the piston
skirt area.
•Assemble it so that R mark faces to top side
of piston.
15) Install the snap ring.
Install the snap rings in the piston holes located op-
posite to the service holes in cylinder block when
positioning all pistons in corresponding cylinders.
NOTE:
Use new snap rings.
16) Installation of piston:
(1) Using the ST1, turn the crankshaft so that #3
and #4 connecting rod small ends are set on the
service hole (A).
ST1 18252AA000 CRANKSHAFT SOCKET
(2) Apply a thin coat of engine oil to piston and
cylinder.
(3) Using the ST2, press-fit the piston into cylin-
der.
ST2 18254AA000 PISTON GUIDE
(A) Rear oil seal
(B) Drive plate installation bolt
ST2ST1
(A)
(B)
ME-00570
180˚
(A)(B)
ME-02066
25˚35˚(C)
(D)
(E)
ME-02067
(A) Front side of vehicle
(A)
#1
#2
#3
#4
#5
#6
ME-00573
ST1(A)
(A)
ME-00574
ST2
ME-00576
Page 1932 of 2453

ME(H6DO)-66
Cylinder Block
MECHANICAL
NOTE:
Let the piston front mark (A) face towards the front
of engine.
17) Installing piston pin:
(1) Apply a coat of engine oil to ST3 before in-
sertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 18253AA000 PISTON GUIDE
(2) Apply a coat of engine oil to piston pin, and
insert the piston pin into piston and connecting
rod through service hole.
(3) Using the ST4, install the snap ring.
ST4 18233AA000 PISTON PIN SNAP RING PLI-
ERS
NOTE:
Use new snap rings.
(4) Similarly install the #1, #2, #5 and #6 pis-
tons.
18) Install the service hole plug and O-ring.
NOTE:
Use new O-rings.
19) Apply liquid gasket to the mating surface of oil
pan upper.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
Applying liquid gasket diameter:
Full line part
3.0±1.0 mm (0.12±0.04 in)
Broken line part
1.0 mm (0.04 in)
NOTE:
Use new O-rings.
20) Temporarily tighten the oil pan upper.
NOTE:
Do not install the bolts in wrong place.
(A)
ME-02076
ST3
ME-00577
ST4
ME-00564
(A) O-ring
(A) M8 × 40
(B) M8 × 65
(C) M8 × 85
(D) M8 × 130
(E) M8 × 24
*: Coating
ME-02068
(A)(A)
(A)
(A)
ME-02069
(D)(E)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(E)
(A)(A)(A)
(C)(B)
(A)
(D)
(A)
(A)
(A)
(A)
(A)
(B)
Page 1933 of 2453
ME(H6DO)-67
Cylinder Block
MECHANICAL
21) Tighten the oil pan upper installing bolts in the
numerical order as shown in the figure.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
22) Install the oil strainer.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
23) Apply liquid gasket to the matching surface of
oil pan lower.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
Applying liquid gasket diameter:
5.0±1.0 mm (0.20±0.04 in)
24) Tighten the oil pan lower installing bolts in the
numerical order as shown in the figure.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
25) Install the crankshaft sensor bracket.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
ME-02070
(19)
(14)
(12)
(16)
(24)(22)
(27)
(25)
(21)
(17)
(13)
(11)
(15)
(23)
(26)
(20)
(18)
(7)(6)(9)
(8) (10)
(5)
(3)
(4)
(1)
(2)
LU-02108
ME-00581
(1)(2)
(3)
(4)
(5)
(6)
(7)(8)(9)
(10)
(11)
(12)
(13)(14)
(15)
ME-00582
ME-00559
Page 1934 of 2453
ME(H6DO)-68
Cylinder Block
MECHANICAL
26) Install the crankshaft sensor plate.
27) Install the drive plate.
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
81 N·m (8.3 kgf-m, 60 ft-lb)
28) Install the cylinder head.
57, INSTALLATION, Cylinder Head.>
29) Install the camshaft.
INSTALLATION, Camshaft.>
30) Install the rear chain cover.
ME(H6DO)-51, INSTALLATION, Rear Chain Cov-
er.>
31) Install the crank sprocket.
Sprocket.>
32) Install the cam sprocket.
49, INSTALLATION, Cam Sprocket.>
33) Install the timing chain assembly.
Chain Assembly.>
34) Install the front chain cover.
Chain Cover.>
35) Install the crank pulley.
Pulley.>
ME-00558
ME-02664
ST
Page 1935 of 2453
ME(H6DO)-69
Cylinder Block
MECHANICAL
C: DISASSEMBLY
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using piston ring ex-
pander.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Snap ring
(1)
(1)
(2)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
ME-02097
Page 1936 of 2453

ME(H6DO)-70
Cylinder Block
MECHANICAL
D: ASSEMBLY
1) Apply oil to the surfaces of the connecting rod
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
NOTE:
Position each connecting rod with the marking side
facing forward.
3) Install the connecting rod cap.
Make sure the arrow mark on connecting rod cap
facing front during installation.
CAUTION:
•Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
•When tightening the connecting rod bolts,
apply oil on the threads and flange end.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Install the second ring and top
ring using piston ring expander.
(1) Connecting rod cap (5) Oil ringTightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod bearing (6) Snap ringT: 53 (5.4, 39)
(3) Top ring (7) Connecting rod
(4) Second ring
(1)
(1)
(2)
(2)
(2)
(7)
(3)
(4)(5)
(7)
(3)
(4)
(5)
(6)
(6)T
T
ME-02459