Disassembly
note
●

Use fender covers to avoid damaging painted surfaces.

●

To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.

●

When handling a metal gasket, be careful not to fold the gasket or damage the contacting surface of the gasket.

●

To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

caution
●

Mark all wiring and hoses to avoid misconnection.

●

Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.

1.

Remove the engine and transaxle assembly.

(Refer to Engine And Transmission Assembly - "Engine And Transaxle Assembly")

2.

Remove the transaxle assembly from the engine assembly.

(Refer to Manual Transaxle System - "Manual Transaxle")

3.

Remove the flywheel.

(Refer to Cylinder Block Assembly - "Flywheel")

4.

Remove the rear oil seal.

(Refer to Cylinder Block Assembly - "Rear Oil Seal")

5.

Install the engine assembly to engine stand for disassembly.

6.

Remove the cylinder head cover.

(Refer to Cylinder Head Assembly - “Cylinder Head Cover”)

7.

Remove the thermostat housing.

(Refer to Cooling System - “Thermostat”)

8.

Remove the timing chain.

(Refer to Timing System - “Timing Chain”)

9.

Remove the intake manifold.

(Refer to Intake And Exhaust System - "Intake Manifold")

10.

Remove the exhaust manifold.

(Refer to Intake And Exhaust System - "Exhaust Manifold")

11.

Remove the cylinder head.

(Refer to Cylinder Head Assembly - “Cylinder Head”)

12.

Remove the oil pan and the oil screen.

(Refer to Lubrication System - “Oil pan”)

13.

Remove the ladder frame (A).

Insert the blade of SST (09215-3C000) between the cylinder block and the ladder frame and cut out applied sealer. Then, remove the ladder frame.

note
●

Insert the SST between the cylinder block and the ladder frame by tapping it with a plastic hammer in the direction of (1) arrow.

●

After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the ladder frame, remove it from the cylinder block.

●

Do not turn over the SST abruptly without tapping as it may damage the SST.

●

Be careful not to damage the contacting surfaces of cylinder block and ladder frame.

14.

Check the connecting rod side clearance.

(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")

15.

Check the connecting rod cap oil clearance.

(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")

16.

Remove the piston and connecting rod assemblies.

(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

17.

Check the main bearing oil clearance.

(Refer to Cylinder Block Assembly - "Crankshaft")

18.

Check the crankshaft end play.

(Refer to Cylinder Block Assembly - "Crankshaft")

19.

Remove the crankshaft.

(Refer to Cylinder Block Assembly - "Crankshaft")

20.

Remove the water jacket insert.

(Refer to Cylinder block - "Water Jacket Insert")

21.

Remove the oil jet (A).

Inspection
1.

Remove the gasket material.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2.

Clean the cylinder block.

Using a soft brush and solvent, thoroughly clean the cylinder block.

3.

Inspect the top surface of the cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.05 mm (0.002 in),

Less than 0.02 mm (0.0008 in) / 100 x 100 (3.937 x 3.937in)

4.

Inspect the cylinder bore.

Visually check the cylinder for vertical scratches.

If deep scratches are present, replace the cylinder block.

5.

Inspect the cylinder bore diameter.

Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Standard diameter :

71.00 ~ 71.03 mm (2.7952 ~ 2.7964 in)

6.

Check the cylinder bore size code on the cylinder block.

Cylinder Block Specifications

Class

Mark

Inside Diameter

a

A

71.00 ~ 71.01 mm

(2.79528 ~ 2.79567 in.)

b

B

71.01 ~ 71.02 mm

(2.79567 ~ 2.79606 in.)

c

C

71.02 ~ 71.03 mm

(2.79606 ~ 2.79646 in.)

7.

Check the piston size code on the piston top face.

Piston Outer Diameter

Class

Mark

Inside Diameter

a

A

70.965 ~ 70.975 mm

(2.79390 ~ 2.79429 in.)

b

B

70.975 ~ 70.985 mm

(2.79429 ~ 2.79469 in.)

c

C

70.985 ~ 70.995 mm

(2.79469 ~ 2.79508 in.)

8.

Select the piston corresponding to cylinder bore class.

Clearance : 0.025 ~ 0.045 mm (0.00098 ~ 0.00177 in.)

Reassembly
1.

Install the oil jet (A).

Tightening torque :

8.8 ~ 12.7 N.m (0.9 ~ 1.3 kgf.m, 6.5 ~ 9.4 lb-ft)

2.

Install the water jacket insert.

(Refer to Cylinder block - "Water Jacket Insert")

3.

Install the crankshaft.

(Refer to Cylinder Block Assembly - "Crankshaft")

4.

Check the crankshaft end play.

(Refer to Cylinder Block Assembly - "Crankshaft")

5.

Check the main bearing oil clearance.

(Refer to Cylinder Block Assembly - "Crankshaft")

6.

Install the piston and connecting rod assemblies.

(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

7.

Check the connecting rod cap oil clearance.

(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")

8.

Check the connecting rod side clearance.

(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")

9.

Install the ladder frame.

(1)

Using a gasket scraper, remove all the old packing material.

note

Be careful not to damage the contacting surfaces.

(2)

Install the O-ring (A) to cylinder block.

(3)

Before assembling the ladder frame, the liquid sealant should be applied on ladder frame.

Assemble the part within 5 minutes of applying sealant.

Bead width : 2.5 ~ 3.5 mm (0.1 ~ 0.14 in)

(4)

Install and uniformly tighten the ladder frame bolts in several passes.

Tightening torque :

19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

10.

Assemble the remaining parts in the reverse order of disassembly.

caution

In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block.

●

Crankshaft main bearing selection

(Refer to Cylinder Block Assembly - "Crankshaft")

●

Piston selection

(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

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