Disassembly

Disassembly

1. M/T : remove flywheel.
2. A/T : remove drive plate.
3. Install engine to engine stand for disassembly.
4. Remove timing belt.
5. Remove cylinder head.
6. Remove oil level gauge assembly (A).




7. Remove knock sensor.
8. Remove oil pressure sensor (A).




9. Remove water pump.
10. Remove oil pan.
11. Remove oil screen.
Remove the 2bolts(C), oil screen (A) and gasket (B).




12. Check the connecting rod end play.
13. Remove the connecting rod caps and check oil clearance.
14. 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.

15. Remove front case.
16. Remove rear oil seal case.
Remove the 5 bolts(B) and rear oil seal case (A).




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

NOTE:
Arrange the main bearings and trust washers in the correct order.




20. 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.
21. Remove piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove the 2side rails and oil ring by hand.

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

22. Disconnect connecting rod from piston.