Disassembly

Disassembly

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Turn the crankshaft pulley so that the No.1 piston is at top dead center.
- Engine removal is required for this procedure.

1. Remove the engine assembly from the vehicle.
2. Install the engine to engine stand for disassembly.
3. Remove the intake manifold and exhaust manifold.
4. Remove the timing chain.
5. Remove the cylinder head assembly.
6. Remove the drive plate (AT only) or fly wheel (MT only).
7. Remove the oil pump.
8. Remove the A/C compressor.
9. Remove the alternator (A).




10. Remove the power steering pump and the bracket.




11. Remove the water pump (A) and the water pump gasket.




12. Remove the tensioner assembly integrated bracket (A).




13. Remove the oil level gauge (A).




14. Remove the knock sensor (A).




15. Remove the oil pressure sensor (A).




16. Remove the CKP sensor (A).




17. Remove the ladder frame (A).




18. Check the connecting rod end play.
19. Remove the connecting rod caps and check oil clearance.
20. Remove piston and connecting rod assemblies.
(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.

NOTE:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.

21. Remove crankshaft bearing cap and check oil clearance.
22. Check the crankshaft end play.
23. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

NOTE:
Arrange the main bearings and thrust bearings in the correct order.




24. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
25. Remove piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove 2 side rails and the spacer by hand.

NOTE:
Arrange the piston rings in the correct order only.

26. Disconnect connecting rod from piston.