21.
Remove the piston cooling oil jets (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, take care not to fold the gasket or damage the contact 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 from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
Remove the transaxle assembly from the engine assembly.
Manual Transaxle : (Refer to Manual Transaxle System - "Manual Transaxle")
Automatic Transaxle : (Refer to Automatic Transaxle System - "Automatic Transaxle")
Manual Transaxle : Remove the flywheel.
(Refer to Cylinder Block - "Flywheel")
Automatic Transaxle : Remove the drive plate.
(Refer to Cylinder Block - "Drive Plate")
Remove the encoder and the rear oil seal case assembly.
(Refer to Cylinder Block - "Rear Oil Seal")
Install the engine assembly to engine stand for disassembly.
Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
Remove the EGR & thermostat housing assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
Remove the lower oil pan and upper oil pan.
(Refer to Lubrication System - "Oil Pan")
Remove the balance shaft & oil pump module.
(Refer to Lubrication System - "Balance Shaft & Oil Pump")
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
Remove the high pressure fuel pump.
(Refer to Engine Control/Fuel System - "High Pressure Pump")
Remove the water pump assembly.
(Refer to Cooling System - "Water Pump")
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 piston cooling oil jets (A).
Using a gasket scraper, remove all the gasket material from the top surface of 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) for total area
Less than 0.012 mm (0.0005 in) for a section of 50 mm x 50 mm (1.9685 in x 1.9685 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.
Cylinder bore diameter
2.0L : 84.000 ~ 84.030 mm (3.3071 ~ 3.3083 in)
2.2L : 85.400 ~ 85.430 mm (3.3622 ~ 3.3634 in)
Select a piston cooling oil jet using the selection chart.
If the parts is not matched, it may cause of engine adhere due to insufficient oil pressure.
Selection Chart For Piston Cooling Oil Jet and Balance shaft & Oil Pump Module
BSM type
α (Cap color : Yellow) | β (Cap color : Black) |
 |  |
Piston cooling oil jet type
A (Cap color : None) | B (Cap color : Orange) |
 |  |
Install the piston cooling oil jets (A).
Tightening torque :
8.8 ~ 12.7 N.m (0.9 ~ 1.3 kgf.m, 6.5 ~ 9.4 lb-ft)
Assemblel the other 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")
