20.
Remove the oil jet (A).
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.
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.
Remove the engine and transaxle assembly.
(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")
Remove the transaxle assembly from the engine assembly.
(Refer to Manual Transaxle System - "Manual Transaxle")
Remove the flywheel.
(Refer to Cylinder Block - "Flywheel")
Remove the rear oil seal.
(Refer to Cylinder Block - "Rear Oil Seal")
Install the engine to engine stand for disassembly.
Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
Remove the EGR cooler.
(Refer to Intake And Exhaust System - “EGR Cooler”)
Remove the thermostat housing.
(Refer to Cooling System - “Thermostat”)
Remove the water pump and the water return pipe.
(Refer to Cooling System - “Water Pump”)
Remove the timing chain.
(Refer to Timing System - “Timing Chain”)
Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
Remove the oil filter & cooler assembly.
(Refer to Lubrication System - “Oil Filter & Cooler Assembly”)
Check the connecting rod side clearance.
(Refer to Cylinder Block - "Piston and Connecting Rod")
Check the connecting rod cap oil clearance.
(Refer to Cylinder Block - "Piston and Connecting Rod")
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
Check the main bearing oil clearance.
(Refer to Cylinder Block - "Crankshaft")
Check the crankshaft end play.
(Refer to Cylinder Block - "Crankshaft")
Remove the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
Remove the oil jet (A).
Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
Inspect the top surface of 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 :
Less than 0.05 mm (0.0020 in)
Inspect the cylinder bore. Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
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 :
1.4 L : 75.000 ~ 75.030 mm (2.9527 ~ 2.9539 in)
1.6 L : 77.200 ~ 77.230 mm (3.0394 ~ 3.0405 in)
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)
Assemble the remaining parts in the reverse order of disassembly.
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 - "Crankshaft")
Piston selection
(Refer to Cylinder Block - "Piston and Connecting Rod")
