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ENGINE STAND SETTINGEM-103
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UNIT DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
SettingINFOID:0000000006289579
NOTE:
Explained here is how to disassemble with engine stand s
upporting transmission surface. When using a differ-
ent type of engine stand, note the difference in the steps, etc.
1. Remove the engine assembly from the vehicle. Refer to EM-98, "
Exploded View".
2. Remove crankshaft pulley. Refer to EM-96, "
FRONT OIL SEAL : Removal and Installation".
NOTE:
The drive plate is fixed with a ring gear stopper [SST: KV10119200 (J-49277)]. Loosen the crankshaft pul-
ley mounting bolts before installing the engine stand.
3. Remove the parts that may restrict installation of engine to a widely used engine stand. Fix crankshaft with a ring gear stopper [SST: KV10119200 (J-49277)]. Loosen drive plate mounting bolt
with power tool.
Check for deformation or damage of drive plate. Refer to EM-115, "
Inspection".
NOTE:
The procedure is described assuming that you us e a widely used engine stand holding the surface, to
which transmission is installed.
4. Remove pilot converter using the pilot bushing puller (commercial service tool), if necessary.
5. Lift the engine with hoist to inst all it onto the widely used engine stand.
CAUTION:
Use an engine stand that has a load capacity [240 kg (529 lb) or more] 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. Refer to EM-30, "
Exploded View".
- Remove fuel injector and fuel tube assembly. Refer to EM-48, "
Exploded View".
- Remove ignition coil. Refer to EM-29, "
Exploded View".
- Remove rocker cover. Refer to EM-33, "
Exploded View".
- Remove exhaust manifold. Refer to EM-40, "
Exploded View".
- Other removable brackets. NOTE:
The figure shows an example of widely used engine stand (A)
that can hold mating surface of transmission with drive plate
removed.
CAUTION:
Before removing the hang ing chains, check the engine
stand is stable and there is no risk of overturning.
6. Drain engine oil. Refer to LU-8, "
Draining".
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EM-104
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ENGINE STAND SETTING
7. Drain engine coolant by removing water drain plug (3) from bothsides of the cylinder block as shown in the figure.
1: Washer
2 : Plug (engine coolant)
4 : Plug (engine oil)
5: Washer
: Engine front
Refer to GI-4, "
Components" for symbol marks in the figure.
Water drain plug torque
: 19.6 N·m (2.0 kg/m, 14 ft-lb)
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ENGINE UNITEM-105
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ENGINE UNIT
DisassemblyINFOID:0000000006289580
1. Remove intake manifold. Refer to
EM-30, "Exploded View".
2. Remove exhaust manifold. Refer to EM-40, "
Exploded View".
3. Remove oil pan (lower). Refer to EM-54, "
Exploded View".
4. Remove ignition coil and spark plug. Refer to EM-23, "
Exploded View".
5. Remove rocker cover. Refer to EM-33, "
Exploded View".
6. Remove timing chain. Refer to EM-61, "
Exploded View".
7. Remove exhaust camshaft and VVEL ladder assembly. Refer to EM-74, "
Exploded View".
8. Remove cylinder head. Refer to EM-86, "
Exploded View".
AssemblyINFOID:0000000006289581
Assemble in the reverse order of disassembly.
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EM-106
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CYLINDER BLOCK
CYLINDER BLOCK
Exploded ViewINFOID:0000000006289582
1. Knock sensor 2. Cylinder block 3. Side bolt
4. Thrust bearing 5. Main bearing (upper) 6. Crankshaft key
7. Crankshaft 8. Main bearing (lower) 9. Main bearing cap
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CYLINDER BLOCKEM-107
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Disassembly and AssemblyINFOID:0000000006289583
DISASSEMBLY
1. Remove the following parts:
Oil pans (lower and upper): Refer to EM-54, "
Exploded View" and EM-57, "Exploded View".
Front cover and timing chain: Refer to EM-61, "
Exploded View".
Cylinder head: Refer to EM-86, "
Exploded View".
2. Remove knock sensor. CAUTION:
Carefully handle knock sensor avoiding shocks.
3. Remove oil filter (for VVEL ladder assembly ) from cylinder block, if necessary. Refer to EM-86, "
Exploded
View".
4. Remove piston and connecting rod assembly as per the following: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-115, "
Inspection".
CAUTION:
Be careful not to drop connecting r od bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Loosen mounting bolts, and remove connecting rod bearing cap.
c. Using a hammer handle (A) or similar tool, push piston and con- necting rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interf erence of the connecting rod big
end.
5. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
Identify installation positions, and store them without mixing them up.
6. Remove piston rings from piston. Before removing piston rings, check the piston ring side clearance. Refer to EM-115, "
Inspection".
10. Main bearing cap sub bolt 11. Main bearing cap bolt 12. Connecting rod cap bolt
13. Connecting rod cap 14. Connecting rod bearing 15. Connecting rod
16. Snap ring 17. Piston pin 18. Piston
19. Oil ring 20. Second ring 21. Top ring
22. Pilot converter 23. Drive plate 24. Reinforcement plate
25. Rear oil seal 26. Rear oil seal retainer 27. O-ring
28. Crankshaft position sensor (POS) 29. Cylinder block heater (for Canada)
A.Comply with the assembly procedure
when tightening. Refer to
EM-107
.B. Chamfered C. Installed on transmission
: Crankshaft side
Refer to GI-4, "
Components" for symbol marks in the figure.
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EM-108
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CYLINDER BLOCK
Use a piston ring expander (commercial service tool) (A).
CAUTION:
When removing piston rings, be careful not to damagepiston.
Be careful not to damage piston rings by expanding them
excessively.
7. Remove piston from connecting rod as per the following:
a. Using snap ring pliers (A), remove snap rings.
b. Heat piston to 60 to 70 °C (140 to 158 °F) with an industrial use
dryer (A) or an equivalent.
c. Push out piston pin using a stick that has an outer diameter of approximately 20 mm (0.79 in).
8. Remove rear oil seal and rear oil seal retainer assembly from cylinder block. Insert screwdriver or similar tool between rear end of crankshaft counter weight and rear oil sealretainer, and separate liquid gasket to remove.
CAUTION:
Be careful not to damage the mating surfaces.
9. Using screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
10. Remove main bearing cap as per the following: Before loosening cylinder block bolts, measure the crankshaft end play. Refer to EM-115, "
Inspection".
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CYLINDER BLOCKEM-109
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a. Loosen side bolts starting from No. 30 to 21 to remove.
b. Loosen main bearing cap sub bolts starting from No. 20 to 11 to
remove.
c. Loosen main bearing cap bolts starting from No. 10 to 1 to remove.
d. Remove the main bearing cap. Insert bolts (1) into bolt holes, and then remove main bearing
cap (2) by lifting up and shaking forward and backward.
CAUTION:
Be careful not to damage the mounting surface.
11. Remove crankshaft.
12. Remove main bearings and thrust bearings from main bearing cap and cylinder block. CAUTION:
Be careful not to drop main bear ing, and to scratch the surface.
Identify installation positions, and store them without mixing them up.
13. Remove pilot converter using the pilot bushing puller (commercial service tool), if necessary.
14. Remove oil jet.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
CAUTION:
Use goggles to protect your eyes.
: Engine front
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EM-110
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CYLINDER BLOCK
2. Install each plug to cylinder block as shown in the figure. Tighten each plug as specified below.
Replace washers (1), (5) with new ones.
Apply sealant to the thread of water drain plug (3).Use Genuine RTV silicone seal ant or equivalent. Refer to
GI-22, "
Recommended Chemical Pr oducts and Sealants".
Apply sealant to the thread of plug (4). Use high strength thread lo cking sealant or equivalent.
Refer to GI-22, "
Recommended Chemical Products and
Sealants".
3. Install pilot converter to crankshaft, if removed. With drift [outer diameter: appr ox. 35 mm (1.38 in)], press-fit
as far as it will go.
Press-fit pilot converter with its chamfering side facing crank- shaft as shown in the figure.
4. Install main bearings and thrust bearings as per the following: CAUTION:
Be careful not to drop main b earing, and to scratch the surface.
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
: Engine front
Refer to GI-4, "
Components" for symbols in the figure.
Part Tightening torque
Plug (2) 78.0 N·m (8.0 kg-m, 58 ft-lb)
Water drain plug (3) 19.6 N·m (2.0 kg-m, 14 ft-lb) Plug (4) 53.9 N·m (5.5 kg-m, 40 ft-lb)
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EMP0569D
: Crankshaft side
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