Disassembly

PREPARATION FOR DISASSEMBLY
1. Remove drive plate as follows:





(a) Uniformly loosen the 8 bolts, in several passes, in the sequence shown.
(b) Remove the 8 bolts, rear plate, drive plate and front spacer.
2. Install engine to a suitable engine stand for disassembly.
3. Remove alternator.
4. Remove timing belt and pulleys.





5. Remove No. 2 water bypass pipe with hose.
6. Remove water pump, refer to Cooling System.
7. Remove cylinder head, refer to Cylinder Head Assembly.





8. Using socket wrench Special Service Tool (SST) No. 09816-30010, or equivalent, remove oil pressure switch and knock sensors, then remove the union nut and gasket.
9. Remove oil filter and bracket assembly.
10. Remove LH engine mounting bracket and insulator assembly.
11. Remove RH engine mounting bracket and insulator assembly.
12. Remove fuel pipe support.
13. Remove oil pump, refer to Engine lubrication.

DISASSEMBLY





1. Remove rear oil seal retainer as follows:
(a) Remove the 6 bolts of the retainer.
(b) Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver.
2. Check connecting rod thrust clearance, refer to Testing and Inspection.








3. Remove connecting rod caps and check oil clearance, refer to Connecting Rod Bearing Testing and Inspection.

NOTE: Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

4. Remove piston and connecting rod assemblies as follows:





(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) 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 correct order

5. Check crankshaft thrust clearance, refer to Crankshaft Main Bearing Testing and Inspection.
6. Remove main bearing caps and check oil clearance.





(a) Uniformly loosen and remove the 14 main bearing cap bolts, in several passes, in the sequence shown.





(b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No. 4 main bearing cap only).

7. Remove crankshaft as follows:





(a) Lift out the crankshaft
(b) Remove the upper bearings and upper thrust washers from the cylinder block.

NOTE: Arrange the main bearing caps, bearings and thrust washers in the correct order.