CYLINDER BLOCK DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the cylinder block 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
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane-keeping assist system (for Mono camera type)

for Stereo Camera type:

Click here

for Mono Camera type:

Click here

Lane control system (for Stereo camera type)
Parking support brake system*1
Pre-collision system (for Mono camera type)
Pre-collision system (for Stereo camera type)
AFS (Front-lighting adaptive system)

    Lighting system (EXT)

  • Cornering lights
Variable gear ratio steering system

Click here

Parking assist monitor system

Click here

Panoramic view monitor system

Click here

Initialize rear door sunshade system Rear door sunshade system

Click here

Initialize power trunk lid system Power trunk lid system

Click here

Replacement of ECM Vehicle Identification Number (VIN) registration DTC P063051 is output

w/ Canister Pump Module

Click here

w/o Canister Pump Module

Click here


  • Throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

  • Cylinder head sub-assembly

  • Camshaft (for intake or exhaust camshaft)

  • Camshaft timing gear assembly

  • Camshaft timing exhaust gear assembly

  • Piston or piston ring

  • Mass air flow meter sub-assembly

  • Fuel injector assembly (for port injection)

  • Fuel injector assembly (for direct injection)

  • Fuel pump assembly (for high pressure side)

  • Air fuel ratio sensor (sensor 1)

  • Air fuel ratio sensor (sensor 2)

  • Engine coolant temperature sensor

  • Spark plug

  • Ignition coil assembly

  • EGR valve assembly

  • Air leaks from intake system

  • Gas leaks from exhaust system

  • Knock control sensor

 Inspection after repairs

  • Poor idle, etc.

  • Engine start function, etc.

w/ Canister Pump Module

Click here

w/o Canister Pump Module

Click here

Replacement of engine assembly Inspection after repair
Drive learning*2

  • Large shift shock

  • Deterioration of fuel efficiency

L310:

Click here

L310F:

Click here

Parts between the steering wheel and tires have been removed/installed, replaced or adjusted Perform Actuator Angle Neutral Point Calibration and Initialization

  • Variable gear ratio steering system

  • Steering wheel off-center

  • DTCs are output

Click here

Front bumper assembly (Including removal and installation)

  • Ultrasonic sensor detection angle

  • Ultrasonic sensor detection angle registration

 Parking support brake system

Click here

Front television camera view adjustment Panoramic view monitor system

Click here

Suspension, tires, etc

  • Ultrasonic sensor detection angle

  • Ultrasonic sensor detection angle registration

 Parking support brake system

Click here


  • Parking assist ECU initialization

  • Adjust steering angle

  • Rear television camera view adjustment (for Rear camera detection system)

 Panoramic view monitor system

Click here

Rear television camera assembly optical axis (Back camera position setting) Parking assist monitor system

Click here

*1: When performing learning using the GTS.
Click here Click here
*2: After performing the confirmation driving pattern, if the shock during acceleration is large after calibrating the "A/T Code Reset", perform driving learning.

PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. B004UR6

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

      Standard thrust clearance
      0.15 to 0.40 mm (0.00591 to 0.0157 in.)
      Maximum thrust clearance
      0.50 mm (0.0197 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. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

      Tech Tips

      The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.

    2. B004RVX

      Remove the 2 connecting rod cap bolts.

    3. B004T16

      Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

    4. Clean the crank pin and bearing.

    5. Check the crank pin and bearing for pitting and scratches.

    6. B004TSAC01
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    7. B004UGPC01
      *a Front Mark
      B004SZX Engine Front

      Check that the front mark of the connecting rod cap is facing forward.

    8. Install the connecting rod cap.

      Click here

      Note

      Do not turn the crankshaft.

    9. Remove the 2 bolts and connecting rod cap.

    10. B004V4NC01
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.045 to 0.067 mm (0.00177 to 0.00264 in.)
      Maximum oil clearance
      0.070 mm (0.00276 in.)

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

      Standard Connecting Rod Diameter
      Mark Specified Condition
      1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
      2 56.007 to 56.012 mm (2.20500 to 2.20519 in.)
      3 56.013 to 56.018 mm (2.20523 to 2.20543 in.)
      4 56.019 to 56.024 mm (2.20547 to 2.20566 in.)
      Standard Connecting Rod Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.482 to 1.485 mm (0.05835 to 0.05846 in.)
      2 1.486 to 1.488 mm (0.05850 to 0.05858 in.)
      3 1.489 to 1.491 mm (0.05862 to 0.05870 in.)
      4 1.492 to 1.494 mm (0.05874 to 0.05882 in.)
      Standard crankshaft pin diameter
      52.992 to 53.000 mm (2.0863 to 2.0866 in.)

      Note

      Completely remove the Plastigage after the measurement.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. B004XNXC01
      *a Ridge Reamer

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

    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

      Tech Tips


      • Keep the bearing, connecting rod and cap together.

      • Arrange the piston and connecting rod assemblies in the correct order.

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings from the connecting rods and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  5. REMOVE CRANKSHAFT


    1. B004SGRN01

      Uniformly loosen and remove the 8 crankshaft bearing cap bolts and 8 seal washers in several steps and in the sequence shown in the illustration.

    2. B004WQ1N01

      Uniformly loosen the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. B004YGP

      Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

      Note


      • Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed.

      • Be careful not to damage the joint surfaces of the cylinder block and the crankshaft bearing cap.

    4. Remove the crankshaft.

  6. REMOVE CRANKSHAFT BEARING


    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET


    1. B004U1A

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

  8. REMOVE PISTON RING SET


    1. B004VPRC01
      *a Piston Ring Expander

      Using a piston ring expander, remove the 2 compression rings.

    2. Remove the oil ring expander and 2 side rails by hand.

      Tech Tips

      Arrange the removed parts in the correct order.

  9. REMOVE PISTON SUB-ASSEMBLY WITH PIN


    1. B004UE7

      Disconnect the connecting rod from the piston.


      1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.

      2. Gradually heat the piston to approximately 80°C (176°F).

      3. B004V2E

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

        Tech Tips


        • The piston and piston pin are a matched set.

        • Arrange the pistons, piston pins, connecting rods and connecting rod bearings in the correct order.

    2. Using a gasket scraper, remove the carbon from the piston top.

    3. Using a groove cleaning tool or broken ring, clean the piston ring grooves.

    4. Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B004Y9U

      Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies.

    2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

      If necessary, replace the No. 1 oil nozzle sub-assembly.

  11. REMOVE CONNECTING ROD SMALL END BUSH


    1. B004WNPN01

      Using SST and a press, press out the connecting rod small end bush.

      SST
      09222-30010