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
Auxiliary battery terminal is disconnected/reconnected	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)	Click here
		Intelligent clearance sonar system*1
		Simple intelligent parking assist system*1
		Pre-crash safety system
		Parking assist monitor system	Click here
	Initialize back door lock	Power door lock control system	Click here
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	Click here
for SFI system (w/ Canister Pump Module) Replacement of ECM	Perform Vehicle Identification Number (VIN) registration	MIL comes on	Click here
for SFI system (w/o Canister Pump Module) Replacement of ECM	Perform Vehicle Identification Number (VIN) or frame number registration	MIL comes on	Click here
for SFI system (w/ Canister Pump Module) Replacement of throttle body assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of piston or piston ring Replacement of fuel injector assembly Replacement of spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Gas leak from exhaust system is repaired Replacement of knock control sensor	Inspection After Repair	Poor idle, etc. Engine start function, etc.	Click here
for SFI system (w/o Canister Pump Module) Replacement of throttle body assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of piston or piston ring Replacement of fuel injector assembly Replacement of spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Gas leak from exhaust system is repaired Replacement of knock control sensor	Inspection After Repair	Poor idle, etc. Engine start function, etc.	Click here
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement)	Ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent clearance sonar system Simple advanced parking guidance system	Click here
	Rear television camera assembly optical axis (Back camera position setting)	Parking assist monitor system	Click here
	Initialize No. 1 headlight ECU sub-assembly LH	Automatic headlight beam level control system	Click here
Front wheel alignment adjustment	Clear zero point calibration data. Perform yaw rate and acceleration sensor zero point calibration.	DTCs are stored ABS warning light illuminates Brake warning light/yellow (minor malfunction) illuminates Slip indicator light illuminates VSC disabled or malfunctions	Click here
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	Click here

*1: When performing learning using the GTS.

Click here

PROCEDURE

REMOVE CYLINDER BLOCK WATER JACKET SPACER
1. Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.
REMOVE NO. 1 VENTILATION CASE
Tech Tips

There are 2 installation types for the No. 1 ventilation case.

Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.
1. Type A:
  1. Remove the 6 bolts and 2 nuts.
  2. *a Protective Tape
    
    Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.
    
    Note
    
    Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.
2. Type B:
  1. Remove the 8 bolts.
  2. *a Protective Tape
    
    Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.
    
    Note
    
    Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. *a Paint Mark
  
  Place a paint mark across each corresponding connecting rod and connecting rod bearing cap.
  
  Tech Tips
  
  The paint marks are used to ensure that the same parts are installed in the same combination to their original locations.
2. Using SST, remove the 8 connecting rod bolts from the connecting rod bearing caps.
  
  SST
  
  09205-16011
3. Using the 2 removed connecting rod bolts, remove the 4 connecting rod caps with connecting rod bearings by wiggling each connecting rod cap left and right.
  
  Tech Tips
  
  Keep the connecting rod bearing installed to the connecting rod cap.
4. Using a ridge reamer, scrape off any carbon on the top of the cylinder.
5. Push out the 4 pistons with 4 connecting rods and 4 connecting rod bearings through the top of the cylinder block sub-assembly.
  Tech Tips
  - Keep the connecting rod bearings, connecting rods and connecting rod caps together.
  - Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE CONNECTING ROD BEARING
1. Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE CRANKSHAFT
1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
2. Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps from the cylinder block sub-assembly by wiggling each crankshaft bearing cap back and forth.
  
  Tech Tips
  
  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.
REMOVE CRANKSHAFT BEARING
1. Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
2. Remove the 5 lower crankshaft bearings from the 5 crankshaft bearing caps.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE UPPER CRANKSHAFT THRUST WASHER
1. Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE PISTON
1. Using a screwdriver, pry out the piston pin hole snap ring from the piston.
  Note
  
  Do not remove the piston pin hole snap ring (rear side) unless it is being replaced.
  
  Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).
2. Gradually heat the piston to approximately 80°C (176°F).
  
  CAUTION:
  
  Be sure to wear protective gloves.
3. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.
  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.
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.