Disassembly and Assembly: Disassembly
- Remove the following parts:
- Oil pans (upper and lower): Refer to "EXPLODED VIEW " and "EXPLODED VIEW ".
- Front and rear timing chain case: Refer to "EXPLODED VIEW " and "EXPLODED VIEW ".
- Cylinder head: Refer to "EXPLODED VIEW ".
- Remove knock sensor.CAUTION: Carefully handle sensor avoiding shocks.
- Remove baffle plate from lower cylinder block.
- Remove piston and connecting rod assembly with the following procedure:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to "INSPECTION ".
CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface.- Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
- Remove connecting rod bearing cap.
- Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
- 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.
- Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Refer to "INSPECTION ".
- Use a piston ring expander (commercial service tool) (A).
CAUTION:- When removing piston rings, be careful not to damage piston.
- Be careful not to damage piston rings by expanding them excessively.
- Remove piston from connecting rod as follows:
- Using snap ring pliers (A), remove snap rings.
- Heat piston to 60 to 70°C (140 to 158°F) with an industrial use dryer (A) or equivalent.
- Push out piston pin using a stick than has an outer diameter of approximately 20 mm (0.79 in).
- Remove lower cylinder block bolts.
- Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to "INSPECTION ".
- Loosen lower cylinder block bolts in the reverse order shown in the figure below in several different steps.
- Remove lower cylinder block as follows:
Screw M8 bolt [pitch: 1.25 mm (0.049 in) length: approximately 50 mm (1.97 in)] into bolt holes (A). Then equally tighten each bolt, and remove lower cylinder block.
CAUTION:- Be careful not to damage the mounting surfaces.
- Never tighten bolts excessively.
- Never insert screwdriver, this will damage the mating surface.
- Remove crankshaft.
- Pull rear oil seal out from rear end of crankshaft.
- Remove main bearings and thrust bearings from cylinder block and lower cylinder block.CAUTION:
- Be careful not to drop main bearing, and to scratch the surface.
- Identify installation positions, and store them without mixing them up.
- Remove oil jet.