Removal

Cylinder Block

Cylinder Block Components (Part 1):

Cylinder Block Components (Part 2):

REMOVAL

NOTE:
Before conducting this procedure, drain the engine oil completely.

1) Remove the intake manifold.
2) Remove the crank pulley.
3) Remove the timing belt cover.
4) Remove the timing belt.
5) Remove the cam sprocket.
6) Remove the crank sprocket.
7) Remove the A/C compressor together with the bracket.
8) Remove the camshaft.
9) Remove the cylinder head.
10) Remove the clutch disc and cover.
11) Remove the flywheel.
12) Remove the oil separator cover.
13) Remove the oil filter.
14) Remove the oil cooler.
15) Remove the water pump.
16) Remove the bolt which secures the oil pump to the cylinder block.

NOTE:
When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.





17) Remove the oil pump from cylinder block using a flat tip screwdriver.

CAUTION:
Be careful not to damage the mating surface of the cylinder block and oil pump.





18) Remove the front oil seal from the oil pump.
19) Remove the clip holding the oil level switch harness from cylinder block.





20) Remove the oil pan and cylinder block lower.
1) Set the part so that the cylinder block LH is on the upper side.
2) Remove the bolts which secure the oil pan to the cylinder block lower.
3) Insert an oil pan cutter blade into the gap between cylinder block lower and oil pan, and remove the oil pan.

CAUTION:
Do not use a screwdriver or similar tools in place of oil pan cutter.

4) Remove the bolts which secure the cylinder block lower to the cylinder block, and remove the cylinder block lower by using flat tip screwdriver.

CAUTION:
Insert the flat tip screwdriver at the position shown in the figure, and avoid scratching the mating surface of the cylinder block and cylinder block lower.





21) Remove the baffle plate.
22) Remove blow-by pipe assembly (A), blow-by pipe (B), PCV hose assembly (C) and water pipe assembly (D).

NOTE:
To unlock the clamp of the blow-by pipe assembly (A), blow-by pipe (B) and PCV hose assembly (C), pinch the clamp by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure.

ST 18353AA000 CLAMP PLIERS








23) Remove the water by-pass pipe.








24) Remove the service hole plugs using a hexagon wrench [14 mm].





25) Remove the service hole cover.
26) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.





27) Draw out the piston pin from #1 and #2 pistons using ST.

ST 499097700 PISTON PIN REMOVER ASSY

NOTE:
Be careful not to confuse the original combination of piston, piston pin and cylinder.





28) Similarly remove the piston pins from #3 and #4 pistons.
29) Remove the cylinder block connecting bolt on the RH side.
30) Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns.
31) Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
32) Separate cylinder block LH and RH.

NOTE:
When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.





33) Remove the rear oil seal.
34) Remove the crankshaft together with connecting rod.
35) Remove the crankshaft bearings from cylinder block using a hammer handle.

NOTE:
^ Press the crankshaft bearing at the end opposite to locking lip to remove.
^ Be careful not to confuse the crankshaft bearing combination.

36) Remove each piston from the cylinder block using a wooden bar or hammer handle.

NOTE:
Be careful not to confuse the original combination of piston and cylinder.