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REMOVAL

REMOVAL

Note

Before conducting this procedure, drain the engine oil completely.


Remove the intake manifold.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the cam sprocket.

Remove the crank sprocket.

Remove the generator and A/C compressor with their brackets.

Remove the rocker cover.

Remove the cylinder head bolts in alphabetical sequence as shown in the figure.

Note

Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling.



(A)

Front side



While tapping the cylinder head with a plastic hammer, separate it from cylinder block.

Remove the bolts (a) and (c) to remove the cylinder head.


(A)

Front side



Remove the cylinder head gasket.

Note

Do not scratch the mating surface of cylinder head and cylinder block.


Similarly, remove the right side cylinder head.

Remove the clutch housing cover. (MT model)

Remove the flywheel (MT model) or drive plate (AT model).

Lock the crankshaft using ST.

ST 32005107 CRANKSHAFT STOPPER


• MT model


• AT model



Remove the oil separator cover.

Remove the water by-pass pipe for heater.

Remove the water pump after loosening the bolts in alphabetical sequence as shown in the figure.


Remove the oil pump from cylinder block.

Use a flat tip screwdriver as shown in the figure when removing the oil pump.

Important

Be careful not to scratch the mating surface of cylinder block and oil pump.



Remove the oil pan.

Place the cylinder block to face the #2 and #4 piston side upward.

Remove the bolts which secure oil pan to cylinder block.

Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.

Note

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



Remove the oil strainer stay.

Remove the oil strainer.

Remove the baffle plate.

Remove the oil filter using ST.

ST 32005021 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in))


Remove the water pipe.



(1)

Service hole plug

(3)

Snap ring

(5)

Service hole cover

(2)

Gasket

(4)

Piston pin

(6)

O-ring



Remove the service hole cover and service hole plugs using a hexagon wrench (14 mm).


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.


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

ST 32005124 PISTON PIN REMOVER

Note

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



Similarly remove the piston pins from #3 and #4 pistons.

Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.

Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.

Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.

Separate the cylinder block (RH) and (LH).

Note

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



(1)

Cylinder block

(3)

Crankshaft

(5)

Piston

(2)

Rear oil seal

(4)

Crankshaft bearing



Remove the rear oil seal.

Remove the crankshaft together with connecting rod.

Remove the crankshaft bearings from cylinder block using a hammer handle.

Note

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


Draw out each piston from cylinder block using a wooden bar or hammer handle.

Note

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