CYLINDER BLOCK DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Battery terminal is disconnected/reconnected Perform steering sensor zero point calibration Lane departure alert system (w/ Steering Control)

Click here

Pre-collision system
Memorize steering angle neutral point Parking assist monitor system

Click here

Replacement of ECM Vehicle Identification Number (VIN) registration MIL comes on

Click here

Perform code registration (Immobiliser system)

  • Wireless door lock control system

  • Smart Entry and Start System (for Entry Function)

  • Smart Entry and Start System (for Start Function)

  • Steering lock function

 See Service Bulletin for the registration method.

  • Replacement of engine assembly

  • Gas leak from exhaust system is repaired

  • Replacement of throttle body with motor assembly

  • Replacement of cylinder head sub-assembly

  • Replacement of camshaft

    (for intake or exhaust camshaft)

  • Replacement of camshaft timing gear assembly

  • Replacement of camshaft timing exhaust gear assembly

  • Replacement of fuel injector assembly

  • Replacement of spark plug

  • Replacement of ignition coil assembly

  • Replacement of knock control sensor

  • Replacement of engine coolant temperature sensor

  • Replacement of piston or piston ring

 Inspection after repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

Replacement of automatic transaxle assembly

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Input transaxle compensation code into ECM

  3. Perform road test to allow ECM to learn

  • Large shift shock

  • The deterioration of fuel efficiency

Click here for U760E Initialization

Click here for U760E Registration

Replacement of ECM

(If possible, read the transaxle compensation code from the previous ECM)

 Possible

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Transfer transaxle compensation code

  3. Perform road test to allow ECM to learn
Impossible

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Reset transaxle compensation code

  3. Perform road test to allow ECM to learn
Replacement of ECM*1 Perform code registration (Immobiliser function)

  • Wireless door lock control system

  • Smart Entry and Start System (for Entry Function)

  • Smart Entry and Start System (for Start Function)

  • Steering lock function

 See Service Bulletin for the registration method.
Replacement of ECM*2 Perform code registration (Immobiliser system)

  • Wireless door lock control system

  • Engine start

 See Service Bulletin for the registration method.
Replacement of automatic transaxle fluid ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly.

Click here

Suspension, tires*3 Rear television camera assembly optical axis (Back camera position setting) Parking assist monitor system

Click here for Initialization

Click here for Calibration
Perform headlight ECU sub-assembly LH initialization Lighting system (EXT)

Click here

Front wheel alignment adjustment Perform system variant learning and acceleration sensor zero point calibration.

  • VSC disabled or malfunctioning

  • DTCs are output

  • Slip indicator light illuminated

  • ABS warning light illuminated

Click here

*1: w/ Smart Entry and Start System
*2: w/o Smart Entry and Start System
*3: The vehicle height changes because of suspension or tire replacement.

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. B0071I7

      Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

      Standard Thrust Clearance
      0.160 to 0.512 mm (0.00630 to 0.0202 in.)
      Maximum Thrust Clearance
      0.512 mm (0.0202 in.)

      Tech Tips

      If the thrust clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. B0070UDC03
      *a Alignment Mark

      Check the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.

    2. B006XQR

      Remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    3. Clean the crank pin and connecting rod bearing.

    4. Check the crank pin and connecting rod bearing for pitting and scratches.

      Tech Tips

      If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.

    5. B007156C07
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. B0070X4C11
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap.

    7. B006XQR

      Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

    8. Install and alternately tighten the 2 connecting rod bolts in several steps.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    9. B0070OBC42
      *a Paint Mark
      B006ZY0 Front of Engine

      Mark the front of each connecting rod bolt with paint.

    10. Tighten the connecting rod bolts 90° as shown in the illustration.

      Note

      Do not turn the crankshaft during the measurement.

    11. Remove the 2 connecting rod bolts and connecting rod cap.

      Tech Tips

      Keep the connecting rod bearing and connecting rod cap together.

    12. B006XSCC09
      *a Plastigage
      *b Number Mark

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.033 to 0.063 mm (0.00130 to 0.00248 in.)
      Maximum Oil Clearance
      0.07 mm (0.00276 in.)

      Note

      Remove the Plastigage completely after the measurement.

      Tech Tips


      • If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

      • If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

      Standard Crank Pin Diameter
      51.492 to 51.500 mm (2.02724 to 2.02756 in.)
      Standard Connecting Rod Big End Inside Diameter
      Mark Specified Condition
      1 54.500 to 54.508 mm (2.14567 to 2.14598 in.)
      2 54.509 to 54.516 mm (2.14602 to 2.14629 in.)
      3 54.517 to 54.524 mm (2.14633 to 2.14661 in.)
      Standard Connecting Rod Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.486 to 1.490 mm (0.0585 to 0.0587 in.)
      2 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
      3 1.495 to 1.498 mm (0.0589 to 0.0590 in.)

    13. Perform the inspection above for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


    1. B007096C02
      *a Ridge Reamer

      Using a ridge reamer, remove all the carbon from the top of each cylinder.

    2. Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.

    3. Push the piston with connecting rod sub-assembly and connecting rod bearing out through the top of the cylinder block sub-assembly.

      Tech Tips


      • Keep the connecting rod bearings, connecting rod sub-assembly and connecting rod cap together.

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings from the connecting rod sub-assembly and connecting rod cap.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. B0070O3

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard Thrust Clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum Thrust Clearance
      0.30 mm (0.0118 in.)

      Tech Tips

      If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.

      Standard Thrust Washer Thickness
      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

  6. REMOVE CRANKSHAFT


    1. B006YOAN11

      Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.

    2. Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

      Tech Tips


      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    3. Remove the crankshaft from the cylinder block sub-assembly.

      Tech Tips

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

    4. Check each crankshaft journal and crankshaft bearing for pitting and scratches.

      Tech Tips

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

  7. REMOVE CRANKSHAFT THRUST WASHER


    1. B0071D7

      Remove the crankshaft thrust washers from the cylinder block sub-assembly.

  8. REMOVE CRANKSHAFT BEARING


    1. Remove the crankshaft bearings and No. 2 crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing caps.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  9. REMOVE CRANKSHAFT PULLEY KEY


    1. Using a screwdriver, remove the 2 crankshaft pulley keys from the crankshaft.

  10. REMOVE PISTON RING SET


    1. B0071BWC13
      *a Piston Ring Expander

      Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.

    2. Remove the oil ring expander, upper side rail and lower side rail by hand.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  11. REMOVE PISTON PIN HOLE SNAP RING


    1. B006YCEC13
      *a Front Mark Cutout Portion
      *b Protective Tape

      Using a screwdriver, pry out the piston pin hole snap ring (front side).

      Note


      • Do not remove the piston pin hole snap ring (rear side) unless it has to be replaced.

      • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).

      Tech Tips

      Tape the screwdriver tip before use.

  12. REMOVE PISTON


    1. B0070GV

      Gradually heat each piston to between 80 and 90°C (176 to 194°F).

    2. B0070I0

      Using a brass bar and a hammer, lightly tap out the piston pin. Then remove the connecting rod sub-assembly.

      Tech Tips


      • The piston and piston pin are a matched set.

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B006Y6T

      Using a 5 mm hexagon wrench, remove the 2 bolts and 2 No. 1 oil nozzle sub-assemblies.

  14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. B0070ZO

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies.

  15. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. B0070W8

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts.