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
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 LKA/LDA system

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Parking support brake system*
Pre-collision system
Adaptive high beam system

    Lighting system (EXT)

  • Cornering lights
Variable gear ratio steering system

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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

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  • Throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

  • Cam timing control motor with EDU assembly (Including removal and installation)

  • Camshaft timing intake gear assembly (Including removal and installation)

  • Cylinder head sub-assembly

  • Camshaft (for intake or exhaust camshaft)

  • Camshaft timing exhaust gear assembly

  • Piston

  • Port fuel injector assembly

  • Direct fuel injector assembly

  • Fuel pump (for low pressure side)

  • Fuel pump assembly (for high pressure side)

  • No. 2 fuel pressure sensor (for low pressure side)

  • Fuel pressure sensor (for high pressure side)

  • Air fuel ratio sensor (sensor 1)

  • Air fuel ratio sensor (sensor 2)

  • Spark plug

  • Ignition coil assembly

  • Air leaks from intake system

  • Gas leaks from exhaust system

  • Knock control sensor

  • Turbocharger sub-assembly

 Inspection after repairs

  • Poor idle, etc.

  • Engine start function, etc.

w/ Canister Pump Module:

Click here

w/o Canister Pump Module:

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Piston ring Inspection after repair

  • Poor idle, etc.

  • Engine start function, etc.

    Heavy Knock History

  • Initializes the stored history data

 -
Replacement of engine assembly Inspection after repair

  • Poor idle, etc.

  • Engine start function, etc.

w/ Canister Pump Module:

Click here

w/o Canister Pump Module:

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  • Reset memory

  • Perform road test to allow ECM to learn

  • Large shift shock

  • Deterioration of fuel efficiency

for AGA0E:

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for AGA0F:

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

w/ Canister Pump Module:

Click here

w/o Canister Pump Module:

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    Heavy Knock History

  • Save history

  • Write history

 -
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

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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

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Suspension, tires, etc

  • Ultrasonic sensor detection angle

  • Ultrasonic sensor detection angle registration

 Parking support brake system

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  • Parking assist ECU initialization

  • Adjust steering angle

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

 Panoramic view monitor system

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

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*: When performing learning using the GTS.
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Note

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE


  1. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. B006CZD

      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. B006GCWC01
      *a Matchmarks

      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. Remove the 2 connecting rod cap bolts.

    3. B006FT9

      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. B006CK2C01
      *a Plastigage

      Lay a strip of Plastigage on the crank pin.

    7. B006BCZC01
      *a for Bank 1 (Piston RH)
      *b for Bank 2 (Piston LH)
      *c Piston Matchmark (Protrusion)
      B006AHR Engine Front

      Check that the piston matchmark (protrusion) of the connecting rod cap is facing forward.

      Note


      • Take care as the piston matchmark (protrusion) on the piston RH connecting rod is reversed for the piston LH.

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

    8. Install the connecting rod cap.

      Click here

      Note

      Do not turn the crankshaft.

    9. Remove the 2 bolts and connecting rod cap.

    10. B006A4MC01
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.047 to 0.075 mm (0.00185 to 0.00295 in.)
      Maximum oil clearance
      0.080 mm (0.00315 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 58.400 to 58.406 mm (2.29920 to 2.29944 in.)
      2 58.407 to 58.412 mm (2.29948 to 2.29968 in.)
      3 58.413 to 58.418 mm (2.29971 to 2.29991 in.)
      4 58.419 to 58.424 mm (2.29991 to 2.30015 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
      55.392 to 55.400 mm (2.1808 to 2.1810 in.)

      Note

      Completely remove the Plastigage after the measurement.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. 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 sub-assembly.

      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. B006B20E01

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

    2. B006DEWC01
      *a Protective Tape

      Using a screwdriver, pry out the crankshaft bearing cap sub-assembly.

      Note


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

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

      Tech Tips

      Tape the screwdriver tip before use.

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

    4. B006ALI

      Remove the gasket from the crankshaft bearing cap sub-assembly.

  6. REMOVE CRANKSHAFT BEARING


    1. Remove the crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing cap sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET


    1. B006DZ2

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

  8. REMOVE PISTON RING SET


    1. B0069K5C01
      *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. Disconnect the connecting rod from the piston.


      1. B006FIW

        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. B006E0M

        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. B006DKP

      Using a 5 mm hexagon wrench, remove the 6 bolts and No. 1 oil nozzle sub-assemblies.

    2. Check the 6 No. 1 oil nozzle sub-assemblies for damage or clogging.

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

  11. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY (w/ GPF)


    1. B006E4Q

      Remove the bolt and oil pressure switching valve assembly from the cylinder block insert spacer.

  12. REMOVE CYLINDER BLOCK INSERT SPACER


    1. B006AFIC01
      *A w/ GPF
      *B w/o GPF

      Remove the cylinder block insert spacer and gasket from the cylinder block sub-assembly.

  13. REMOVE CYLINDER BLOCK PLUG WITH HEAD STRAIGHT SCREW


    1. B006DJX

      Using a 10 mm hexagon socket, remove the cylinder block plug with head straight screw and gasket from the cylinder block sub-assembly.

  14. REMOVE NO. 1 PLUG WITH HEAD TAPER SCREW


    1. B006BGE

      Remove the No. 1 plug with head taper screw from the cylinder block sub-assembly.

  15. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (w/ GPF)


    1. B006GY1

      Using a 27 mm deep socket wrench, remove the oil pressure sender gauge assembly.