DISASSEMBLY
- Remove the spark plug. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S41500326862011011400000) ".
- Remove the valve lifter. Identify the installation positions, and store them without mixing them up.
- Remove the valve collet using Tools. Tool number : KV10116200 (J-26336-A) : KV10115900 (J-26336-20) : KV10109220 (-) CAUTION: When working, take care not to damage valve lifter holes.
- Remove the valve spring retainer, valve spring and valve spring seat.
- Inspect the valve guide clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S24265273332011011400000) ".
- Push the valve stem to the combustion chamber side, and remove the valve. Identify the installation positions, and store them without mixing them up.
- Remove the valve oil seal using Tool. Tool number : KV10107902 (J-38959)
- Replace the valve seat if necessary. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S24265273332011011400000) ".
- Replace the valve guide if necessary. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S24265273332011011400000) ".
- Remove the spark plug tube, as necessary. Remove the spark plug tube out of the cylinder head using suitable tool. CAUTION: Do not damage the cylinder head. Do not remove the spark plug tube unless absolutely necessary. Once removed, the spark plug tube will be deformed and cannot be reused.
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- Install the valve guide if necessary. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S24265273332011011400000) ".
- Install the valve seat if necessary. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S24265273332011011400000) ".
- Install the valve oil seal using Tool. Tool number : KV10115600 (J-38958) Apply new engine oil on the new valve oil seal joint and seal lip. Install the valve oil seal to the specified height "H". Height "H" (without valve spring installed) Intake and exhaust : 14.300 - 14.900 mm (0.5630 -0.5870 in)
- Install the valves in their original position.
- Install the valve spring seats.
- Install the valve springs. Install the narrow pitch end (paint mark side) to the cylinder head side.
- Install the valve spring retainers.
- Install the valve collet using Tools. Tool number : KV10116200 (J-26336-A) : KV10115900 (J-26336-20) : KV10109220 (-) CAUTION: When working, take care not to damage valve lifter holes.
- Install the valve lifters. Install the removed parts in their original locations. If installing new lifters, select the correct size lifter for proper valve clearance. Refer to " «VALVE CLEARANCE»(ref-382166-S33641870782011011400000) ".
- Install the spark plug tube if necessary, following the procedure below. Remove any old liquid gasket adhering to the cylinder-head spark plug tube hole. Apply liquid gasket to area within approximately 12 mm (0.47 in) from the edge of the spark plug tube press-fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-382152-S15373783892011011400000) ". Press-fit the spark plug tube to the specified height "H" using suitable tool. Standard press-fit height "H" :38.400 - 39.400 mm (1.512 - 1.551 in) CAUTION: When press-fitting, take care not to deform the spark plug tube. After press-fitting, wipe off any liquid gasket protruding onto the cylinder-head upper face.
- Install the spark plugs.
Scheme 117
- Remove any oil, scale, gasket, sealant and carbon deposits from the cylinder head surface. CAUTION: Do not allow any debris to enter the oil or coolant passages.
- Measure the bottom surface of the cylinder head for distortion in six directions as shown in the figure, using suitable tools. Standard : 0.03 mm (0.0012 in) Limit : 0.1 mm (0.004 in) If measurement exceeds the limit, replace the cylinder head.
Scheme 118
- Check the dimensions of each valve. Refer to " «STANDARD AND LIMIT»(ref-382166-S15428287382011011400000) ".
- If the dimensions are out of the standard, replace the valve.
Note. Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, some steps may be different.
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- Remove engine assembly and mount to engine stand. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S24161808992011011400000) ". CAUTION: Before removing the hanging chains, make sure engine stand is stable and there is no risk of overturning.
- Drain engine oil. Refer to " «CHANGING ENGINE OIL»(ref-382188-S35512646452011011400000) ".
- Drain engine coolant by removing the cylinder block drain plugs "A", "B", "C" and "D" as shown in the figure.
- Remove the following components and associated parts (the parts referred to in step 1 are not included here). Oil pan (upper and lower) and oil strainer. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S32792634892011011400000) ". Crankshaft pulley, front cover and timing chain. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S04198421332011011400000) ". Camshaft. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S09349934232011011400000) ". Cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S23025558552011011400000) ".
- Remove knock sensor and sub harness. CAUTION: Carefully handle sensor, avoiding shocks.
- Check connecting rod side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S10132958172011011400000) ".
- Remove piston and connecting rod assembly as follows. Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center. Remove connecting rod cap. Push the piston and connecting rod assembly out to the cylinder head side using suitable tool.
- Remove connecting rod bearings. CAUTION: When removing them, note the installation position. Keep them in the correct order.
- Check piston ring side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S10132958172011011400000) ".
- Remove piston rings from piston using suitable tool. CAUTION: Do not damage piston. Do not damage piston rings by expanding them excessively.
- Remove piston from connecting rod as follows. Remove snap ring using suitable tool. Heat piston to 60° to 70°C (140° to 158°F) using suitable tool. Push out piston pin using suitable tool.
- Separate and remove rear oil seal retainer from cylinder block. CAUTION: Do not damage mating surface.
- Remove rear oil seal from rear oil seal retainer.
- Measure the crankshaft side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S10132958172011011400000) ".
- Remove main bearing caps as follows: Loosen bolts in several different steps. Loosen side bolts (M10) starting from 30 to 21 to remove. Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to remove. Loosen main bearing cap bolts (M12) starting from 10 to 1 to remove. Remove main bearing cap. Insert bolts (2) into bolt holes, and then remove main bearing cap by lifting up and shaking forward and backward.
- Remove crankshaft.
- Remove the main bearings and thrust bearings from the cylinder block and main bearing caps. When removing them, note the installation position. Keep them in the correct order.
- Remove pilot converter using Tool if necessary. Tool number : ST16610001 (J-23907)
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- Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove any foreign material. WARNING: Use goggles to protect your eyes.
- Install each plug to the cylinder block (only screw-type plugs are shown in the figure). Apply liquid gasket. Use Genuine Thread Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-382152-S15373783892011011400000) ". Replace copper washers with new ones. Tighten each plug as specified below. TORQUE SPECIFICATION Part Washer Tightening torque A Yes 53.9 N.m (5.5 kg-m, 40 ft-lb) B No 19.6 N.m (2.0 kg-m, 15 ft-lb) C Yes 62.7 N.m (6.4 kg-m, 46 ft-lb) D Yes 62.7 N.m (6.4 kg-m, 46 ft-lb)
- Install main bearings and thrust bearings. Remove any dust, dirt, and oil on the bearing mating surfaces of the cylinder block and main bearing caps. Install thrust bearings to both sides of the No. 3 journal housing on the cylinder block and main bearing caps Install thrust bearings with the oil groove facing the crankshaft arm (outside). Install thrust bearings with a protrusion in the center on the main bearing caps. Install main bearings paying attention to the direction. Install the one with oil holes onto the cylinder block and the one without oil holes onto the main bearing cap. Before installing bearings, apply engine oil to bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it. When installing, align the bearing stopper to the notch. Ensure the oil holes on the cylinder block and those on the corresponding bearing are aligned.
- Install pilot converter to the crankshaft using suitable tool.
- Install crankshaft to the cylinder block. While turning crankshaft by hand, make sure it turns smoothly.
- Install main bearing caps. Align the identification number to the journal position to install. Install it with the front mark (indicated by the arrow) in the figure facing the front of engine. Tap caps lightly to seat them in the installation position.
- Follow the steps below to tighten each main bearing cap bolt. Apply engine oil to threads and seating surfaces of bolts, and tighten all bolts temporarily. Main bearing cap bolts in order of 1 to 10 : 39.2 N.m (4.0 kg-m, 29 ft.-lb) Main bearing cap sub bolts in order of 11 to 20 : 29.4 N.m (3.0 kg-m, 22 ft-lb) Measure tightening angle using Tool. Tool number : KV10112100 (BT-8653-A) CAUTION: Measure tightening angle using Tool. Do not measure visually. Main bearing cap bolts in order of 1 to 10 : 40° Main bearing cap sub bolts in order of 11 to 20 : 30° Side bolts in order of 21 to 30 : 49 N.m (5.0 kg-m, 36 ft-lb) Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly. Check crankshaft side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S10132958172011011400000) ".
- Install rear oil seal to rear oil seal retainer. CAUTION: Do not damage or scratch outer circumference of oil seal. Install new rear oil seal in the direction shown in the figure below. Tap until flattened with the front edge of the rear oil seal retainer using suitable tool. Fit the rear oil seal until it is level with the rear end surface of rear oil seal retainer.
- Install rear oil seal retainer. Apply liquid gasket thoroughly to rear oil seal retainer as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-382152-S15373783892011011400000) ". Apply new engine oil on the lips of rear oil seal. Do not touch.
- Install the piston to the connecting rod. Install the snap ring to the grooves of the piston rear side. Insert it fully into the groove to install. Install the piston to the connecting rod. Heat piston until piston pin can be pushed in by hand without excess force [approx. 60° to 70 C° (140° to 158 °F)]. From the front to the rear, insert the piston pin into the piston and the connecting rod. Assemble so that the front mark on the piston crown and the oil holes and cylinder No. on the connecting rod are positioned as shown in the figure below. Install the snap ring to the grooves of the piston front side. Insert it fully into the groove to install. After installing, make sure connecting rod moves smoothly.
- Install piston rings. CAUTION: Do not damage piston. Position each ring with the gap as shown in the figure, referring to the piston front mark. Install the second ring with the stamped surface facing upward. Stamped mark Second ring : 2N
- Install the connecting rod bearings to the connecting rod and connecting rod cap. When installing the connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it. When installing, align the connecting rod bearing stopper protrusion with the cutout of the connecting rod to install. Check that the oil holes on the connecting rod and those on the corresponding bearing are aligned.
- Install the piston and connecting rod assembly to the crankshaft using Tool. Tool number : EM03470000 (J-8037) Position the crankshaft pin corresponding to the connecting rod to be installed onto bottom dead center. Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin. Match the cylinder position with the cylinder No. on the connecting rod to install. Install the piston with the front mark on the piston crown facing the front of the engine. CAUTION: Be careful not to damage the crankshaft pin, resulting from an interference of the connecting rod big end.
- Install connecting rod cap. Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap to install.
- Tighten connecting rod bolts using Tool. Tool number : KV10112100 (BT-8653-A) Connecting rod bolts Step 1 : 19.6 N.m (1.5 kg-m, 11 ft-lb) Step 2 : 90° clockwise Apply engine oil to threads and seats of connecting rod bolts. After tightening bolts, make sure the crankshaft rotates smoothly. Check connecting rod side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-382166-S10132958172011011400000) ".
- Install knock sensors. CAUTION: If knock sensor is dropped, replace it with a new one. Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Install it with its connector facing the center of the cylinder block side. Do not tighten knock sensor bolts while holding connector. Make sure knock sensor does not interfere with other parts. Position the sub-harness as shown in the figure before installing intake manifold.
- Installation of the remaining components is in the reverse order of removal.
- Remove engine assembly from engine stand.
- Install drive plate. Align dowel pin of crankshaft rear end with pin holes of each part to install. Install drive plate, reinforcement plate and pilot converter (if not installed in step 4 ) as shown in the figure. Face the chamfered or rounded edge side to the crankshaft.
Scheme 145
- Move the crankshaft fully forward and backward and measure the clearance between the thrust bearings and crankshaft arm using suitable tool. Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in) Limit : 0.30 mm (0.0118 in)
- If measured value exceeds the repair limit, replace the thrust bearings, and measure again. If it still exceeds the repair limit, replace crankshaft also.
Scheme 146
- Measure side clearance between the connecting rod and crankshaft arm using suitable tool. Standard : 0.20 - 0.40 mm (0.0079 - 0.0157 in) Limit : 0.40 mm (0.0157 in)
- If measured value exceeds the repair limit, replace the connecting rod bearings, and measure again. If it still exceeds the repair limit, replace the crankshaft also.
Scheme 147
- Measure diameter of piston pin hole using suitable tool. Standard : 21.993 - 21.999 mm (0.8659 - 0.8661 in)
Scheme 148
- Measure diameter of piston pin using suitable tool. Standard : 21.989 - 21.995 mm (0.8657 - 0.8659 in)