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 engine unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Battery terminal is disconnected/reconnected Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes) Stop and start system

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Memorize steering angle neutral point Panoramic view monitor system

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Initialize back door lock Power door lock control system

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Initialize servo motor Air conditioning system

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Reset slide door close position Power slide door system

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Reset back door close position Power back door system

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Replacement of ECM Perform Vehicle Identification Number (VIN) or frame number registration DTC is stored

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ECU Communication ID Registration (Immobiliser system) Engine start function See Service Bulletin for the registration method.
Perform code registration (Immobiliser system)

  • Wireless door lock control system

  • Smart entry and start system

  • Engine start function

  • Steering lock system

 See Service Bulletin for the registration method.

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Deceleration Sensor 0 Point Calibration

  3. CVT Oil Pressure Calibration

  • DTCs are stored

  • Neutral control is prohibited

  • Deterioration of fuel efficiency

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Replacement of continuously variable transaxle assembly

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Deceleration Sensor 0 Point Calibration

  3. CVT Oil pressure Calibration

  • DTCs are stored

  • Neutral control is prohibited

  • Deterioration of fuel efficiency

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Replacement of CVT fluid ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

  • Replacement of throttle body with motor assembly

  • Replacement of engine 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 engine coolant temperature sensor

  • Replacement of spark plug

  • Replacement of ignition coil assembly

  • Gas leak from exhaust system is repaired

  • Replacement of knock control sensor

  • Replacement of piston or piston ring

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

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Replacement of starter assembly

Note

When the starter assembly is replaced, "ST NO. 1 relay" and "ST NO. 2 relay" must be also replaced.

 Clear Number of Starter Operations Stop and start system

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  • Replacement of continuously variable transaxle assembly

  • Replacement of CVT fluid

 Bleed the oil pump assembly with motor (continuously variable transaxle assembly)
Replacement of battery Switch battery type
Front wheel alignment adjustment

  1. Clear zero point calibration data and store system information.

  2. Perform yaw rate and acceleration sensor zero point calibration and store system information.

  • VSC disabled or malfunctions

  • DTCs are stored

  • Slip indicator light illuminates

  • ABS warning light illuminates

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Work that changes the vehicle height such as replacement or removal/installation of the rear height control sensor sub-assembly LH or replacement of suspension components Initialize headlight light control ECU sub-assembly LH Headlight leveling function

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Removal/installtaion of the radiator grille Television camera view adjustment Panoramic view monitor system

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PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. B006N70

      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.)

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE


    1. B006NM9C03
      *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. B006MU0

      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.

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

    5. B006QF3C07
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    6. B006MGKC11
      *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. B006MU0

      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. B006NIIC42
      *a Paint Mark
      B006LKF 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. Type A:


      1. B006RCRC08
        *a Plastigage
        *b Number Mark

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        0.030 to 0.063 mm (0.00118 to 0.00248 in.)
        Maximum Oil Clearance
        0.07 mm (0.00276 in.)

        Note

        Remove the Plastigage completely after the measurement.

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

        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.

        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. Type B:


      1. B006RCRC08
        *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.

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

        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.

        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.)

    14. Perform the inspection above for each cylinder.

  3. REMOVE PISTON WITH CONNECTING ROD


    1. B006OW8C02
      *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 and connecting rod bearing out through the top of the cylinder block sub-assembly.

      Tech Tips


      • Keep the connecting rod bearings, connecting rod 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 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. B006LYN

      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.)

      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. B006N8HN01

      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.

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

  7. REMOVE CRANKSHAFT THRUST WASHER


    1. B006MJR

      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. B006L6WC13
      *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. B006Q2QC13
      *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. B006PRW

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

    2. B006N81

      Using a brass bar and a hammer, lightly tap out the piston pin. Then 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.

  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B006LGC

      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. B006MZZ

      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. B006L1L

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