Engine Disassembly

Disassembly





1. Remove No.2 engine mount.





2. Remove No.3 engine mount and bracket.
3. Remove starter (three bolts).
4. Remove eight transaxle mounting bolts and separate transaxle from engine.





5. Remove exhaust manifold and coolant bypass pipe.





6. Install engine to SST.
7. Drain engine oil.
8. Remove front and rear engine hangers.
9. Remove generator by loosening adjusting bolt and removing mounting bolts and pivot bolt.





10. Remove intake manifold support bracket.





11. Remove intake manifold.
12. Remove HLA's.





13. Store HLA's upside down in an oil filled container.





14. Loosen cylinder head bolts in two or three steps following order shown in figure.





15. Remove cylinder head by lifting it off from cylinder block. Protect HLA bore with SST(K95A-1000-E) or equivalent. Compress valve springs with SST or equivalent and allow enough room to remove valve locks.





16. Slowly release pressure and remove valve spring from cylinder head.





17. Remove valve seals with SST or equivalent.
18. Repeat same procedure on all 16 valves.
19. Keep valves in correct order if they are to be reused.
20. Mark cylinder so that valves can be installed to their original positions.
21. Remove valves from cylinder head.
22. Remove lower spring seals from cylinder head.





23. Install SST or equivalent. (Clutch disc centering tool and ring gear brake)





24. Loosen each bolt one turn at a time, in a crisscross pattern, until spring tension is released then remove clutch cover and disc.





25. Remove pilot bearing with SST (Bearing puller) or equivalent if necessary.
26. Hold flywheel with SST (Ring gear brake) or equivalent.





27. Remove six bolts to remove flywheel.





28. Remove oil pan mounting bolts.





29. Remove oil pan with a screwdriver or suitable tool as shown in figure.

Caution:
a) Do not force tools between cylinder block and oil pan as this may damage sealing surface.
b) Do not damage sealing surface when removing old sealant





30. Remove oil strainer.
31. Remove timing belt pulley.





32. Remove oil pump mounting bolt and oil pump.





33. Using a screwdriver covered by a rag, remove oil seal from pump cover side.





34. Remove rear cover.





35. Wrap a prying tool with a shop towel and slowly pry out rear oil seal.





36. Remove water pump.





37. Remove oil filter and oil pressure switch.





39. Check top of each cylinder for ridges.

Notice: Failure to remove a ridge before removing piston will result in damaged ring-lands, cracked piston rings, or cracked piston.





40. If a ridge can be felt, use a ridge reamer to remove ridge before attempting to remove piston from cylinder.
41. Rotate engine block so that crankshaft is at Top Dead Center (TDC).
42. Rotate crankshaft so that No.1 and No.4 cylinders are at Bottom Dead Center (BDC).
43. Use a numbering stamp and mark rod cap and connecting rod with their corresponding cylinder number.

Notice: Mark all rods on same side and make a reference mark on block so that rods are installed in correct position and direction. Failure to install rods properly with result in oil starvation, spun bearings, or damaged internal engine components.

44. Rotate crankshaft so that cylinders No.2 and No.3 are at Bottom Dead Center (BDC) and repeat marking procedure.
45. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
46. Remove rod Gaps.

Notice: Cover connecting rod bolts to protect crankshaft journals.





47. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston to release it from cylinder.
48. Repeat this procedure for each cylinder.
49. Mark tops of pistons with corresponding cylinder numbers they were removed from.





50. Using a piston ring expander, remove piston rings.
51. Hold piston upright and gently move connecting rod.





52. Release connecting rod and observe its movement.

Notice: Do not swing connecting rod wildly. Constant, hard contact with piston will cause a bell-mouth condition that will require piston replacement.

53. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and deformation.





54. Remove piston pin clip from ends of piston pin bore.
55. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.

Notice: Do not allow pins to drop to the ground.

56. Remove connecting rod from piston. Keep individual piston, piston pin, and piston pin clips together for reassembly.
57. Mark main bearing caps (front to back) including direction.

Notice: Each main bearing cap is matched to that particular journal. Installing a cap on wrong journal will cause an align bore problem that will require an expensive machine process to correct.





58. Loosen main bearing caps in two or three steps following order shown in figure.
59. Remove main bearing caps.
60. Grasp crankshaft and lift straight out.
61. Remove main bearings and thrust bearings from cylinder block saddles.