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, refer to Timing Components.
Timing Components




5. Remove no. 2 water bypass pipe with hose.
6. Remove water pump. Refer to Water Pump.
Water Pump
7. Remove cylinder head, refer to Cylinder Head Assembly.
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 Oil Pump.
Oil Pump


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 and oil clearance.
Refer to Connecting Rod Bearing/Testing and Inspection/Procedures.
Connecting Rod Bearing

3. 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

4. Check crankshaft thrust clearance and oil clearance.
Refer to Crankshaft Main Bearing/Testing and Inspection/Procedures.
Crankshaft Main Bearing

5. Remove crankshaft as follows:



- Lift out the crankshaft
- 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.

- For Cylinder Block inspection procedures, proceed to Testing and Inspection.
Testing and Inspection

- Refer to Piston, Engine for inspection and replacement procedures.
Piston