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Engine Overhaul>>Remove Engine

Engine Overhaul>>Remove Engine

Components
1. Take Measures to Prevent Gasoline from Spilling Out
(1) Fuel pump connector

2. Remove Battery
3. Drain Coolant
4. Disconnect Connectors and Wire Harness
(1) Engine ECU
(2) Instrument panel junction block
(3) Engine room junction block

5. Remove Vehicle Interior Components

(1) Steering intermediate shaft

6. Disconnect Clamps and Hoses

(1) Brake booster hose
(2) Radiator hose
(3) Heater hose
(4) Air cleaner hose
(5) Air cleaner
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Engine Overhaul>>Remove Engine

Engine Overhaul>>Remove Engine

Components
7. Disconnect Fuel Line
(1) Fuel line

8. Remove Engine Room Components

(1) Shift and select cables
(2) Clutch release cylinder
(3) A/C compressor
(4) Drive belt
(5) Engine mount
(6) Accelerator cable

9. Remove Components from Under Vehicle

10. Set Engine Lifter
11. Remove Engine with Transaxle
(1) Drive shaft
(2) Tie rod end
(3) Exhaust pipe
(4) Stabilizer
(5) Engine
(6) Transaxle
(7) Suspension member
(8) Drive shaft
(9) Engine lifter

12. Disconnect Transaxle

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Engine Overhaul>>Remove Engine

Engine Overhaul>>Remove Engine

Components
13. Remove Clutch, Flywheel
(1) Flywheel
(2) Clutch disc
(3) Clutch cover

14. Install Engine Overhaul Stand

15. Remove Intake and Exhaust Manifold, Alternator

(1) Exhaust manifold heat insulator
(2) Exhaust manifold
(3) Exhaust manifold gasket
(4) Manifold support bracket
(5) Intake manifold gasket
(6) Intake manifold
(7) Alternator
(8) Engine wire
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Engine Overhaul>>Remove Engine

Engine Overhaul>>Disassemble Engine

Components
1. Remove Water Pump Pulley
2. Remove Engine Mounting Bracket
3. Remove Crankshaft Pulley
4. Remove Water Pump
5. Remove Timing Chain Cover
6. Remove Timing Chain
(1) Water pump pulley
(2) Engine mounting bracket
(3) Crankshaft pulley
(4) Water pump
(5) Gasket
(6) Cylinder head cover
(7) Gasket
(8) Timing chain cover
(9) Chain tensioner
(10) Chain tensioner slipper
(11) Chain vibration damper
(12) Timing chain

7. Inspect Timing Chain

Specified value:
Measurement value:

8. Remove Camshaft
(1) Bearing cap
(2) Camshaft
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Engine Overhaul>>Remove Engine

Engine Overhaul>>Disassemble Engine

Components
9. Inspect Camshaft Timing Gear
(1) Lock Pin Operation
Lock Unlock
Lock pin
(2) Timing Gear Operation

10. Remove Camshaft Timing Gear/Sprocket

11. Remove Cylinder Head
12. Remove Cylinder Head Gasket
13. Remove Oil Pan
(1) Camshaft timing gear (with VVT-i)
(2) Camshaft timing sprocket (without VVT-i)
(3) Cylinder head
(4) Cylinder head gasket
(5) Drain plug
(6) Oil pan No.2
(7) Oil strainer
(8) Gasket
(9) Oil pan No.1

14. Remove Oil Seal

(1) Timing chain cover oil seal
(2) Engine rear oil seal
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Engine Overhaul>>Remove Engine

Engine Overhaul>>Disassemble Engine

Inspect Chain Tensioner

Check that the plunger can be moved by finger
Check that the plunger locks

Inspect Camshaft Timing Sprocket

Specified value:
Measurement value:

Inspect Chain Tensioner Slipper and Damper

Specified value:
Measurement value:
Chain tensioner
slipper
Chain vibration
damper

Inspect Cylinder Head Set Bolt

Measurement length
Specified value:
Measurement value:
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Engine Overhaul>>Cylinder Head

Components

1. Remove Valve Lifter

2. Remove Valve
3. Remove Valve Stem Oil Seal
4. Clean Cylinder Head

Inspect Cylinder Head for Flatness

A. Specified value:
Measurement value:

B. Specified value:
Measurement value:

C. Specified value:
Measurement value:

Inspect Cylinder Head for Cracks

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Engine Overhaul>>Cylinder Head

Inspect Clearance
1. Valve guide bushing oil clearance
Specified value:
Measurement value:
Inside diameter Outside Oil clearance
diameter

2. Valve lifter oil clearance

Specified value:
Measurement value:
Inside diameter Outside Oil clearance
diameter

3. Camshaft thrust clearance

Specified value:
Measurement value:
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Intake side

Exhaust side
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Engine Overhaul>>Cylinder Head

Inspect Clearance
4. Camshaft oil clearance
Specified value:
Measurement value:

Intake side

Exhaust side

Inspect Valve
(1) Valve length
Specified value:
Measurement value:

(2) Valve stem outside diameter

Specified value:
Measurement value:

(3) Valve head margin thickness

Specified value:
Measurement value:

Inspect Valve Spring

1. Check state of spring
(1) Free length
Specified value:
17/43 Measurement value:

(2) Deviation
Specified value:
Measurement value:
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Engine Overhaul>>Cylinder Head

Inspect Valve Spring

2. Tension check
Installed tension
Maximum marking tension

Replace Valve Guide Bush

Measure inside diameter of bushing hole with caliper gauge
Specified value:
Measurement value:

Replace Valve Guide Bush

Tap in guide bushing
Specified value:
Measurement value:

Inspect Valve Seat

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Engine Overhaul>>Cylinder Head

Inspect Camshaft
1. Check shaft runout
Specified value:
Measurement value:

Intake side

Exhaust side

2. Check cam lobe height

Specified value:
Measurement value:

Inspect Camshaft
3. Check journal diameter
Specified value:
Measurement value:

Install Valve Seat

1. Install Valve Stem OIl Seal
2. Install Valve
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3. Install Valve Lifter
 22/43

Engine Overhaul>>Cylinder Block

Inspect Clearance
1. Connecting rod thrust clearance
Specified value:
Measurement value:

2. Connecting rod oil clearance

Specified value:
Measurement value:

3. Crankshaft thrust clearance

Specified value:
Measurement value:

Remove Piston
1. Remove carbon from inner walls of cylinder
2. Remove connecting rod bearing cap
3. Remove connecting rod bearing
4. Remove piston

Remove Crankshaft
1. Remove crankshaft
2. Remove thrust bearing
3. Remove bearing
23/43
4. Remove bearing cap
 24/43

Engine Overhaul>>Cylinder Block

Disassemble Piston
1. No.1 Piston ring
2. No.2 Piston ring
3. Oil ring
4. Piston
5. Piston pin
6. Connecting rod

Inspect Cylinder Block for Flatness

Specified value:
Measurement value:

Inspect Clearance
1. Piston clearance
Inside diameter Outside Clearance
diameter
Thrust direction
b a

Axial direction
b
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c

d
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Engine Overhaul>>Cylinder Block

Inspect Clearance
2. Piston pin clearance
Inside diameter Outside Clearance
diameter

3. Crankshaft oil clearance

Specified value:
Measurement value:

Inspect Piston and Piston Ring

1. Clearance of piston ring groove
Specified value:
Measurement value:
Piston ring groove
No.1
Piston ring groove
No.2

2. Piston ring end gap

Specified value:
Measurement value:
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Engine Overhaul>>Cylinder Block

Inspect Bearing Cap Set Bolt

(1) Crankshaft bearing cap set bolts
Specified value:
Measurement value:

(2) Connecting rod bearing cap set bolts

Specified value:
Measurement value:

Inspect Crankshaft
1. Shaft runout
Specified value:
Measurement value:
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Engine Overhaul>>Cylinder Block

Inspect Crankshaft
2. Crankshaft main journal and crank pin diameter
measurement
- Crankshaft main journal
Specified value:
Measurement value:

- Crank pin diameter

Specified value:
Measurement value:

Inspect Crankshaft
3. Inspect timing sprocket wear
Specified value:
Measurement value:
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Engine Overhaul>>Cylinder Block

Install Crankshaft
1. Crankshaft
2. Thrust bearing
3. Bearing
4. Bearing cap

Reassemble Piston
1. Piston ring
2. Oil ring
3. Piston
4. Piston pin
5. Connecting rod

Install Piston
1. Piston with connecting rod
2. Bearing
3. Bearing cap
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Engine Overhaul>>Reassemble Engine

Components
1. Install Oil Pan
(1) Oil pan No.1
(2) Gasket
(3) Oil strainer
(4) Oil pan No.2
(5) Drain plug

2. Install Cylinder Head Gasket

(1) Cylinder gasket
(2) Cylinder block

3. Install Cylinder Head

(1) Cylinder head
(2) Cylinder head gasket
(3) Cylinder block
(4) Knock pin
(5) Cylinder head bolt

4. Install Oil Seal

(1) SST (Oil seal replacer)
(2) Oil seal
(3) Cylinder block
(4) Timing chain cover
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Engine Overhaul>>Reassemble Engine

Components
5. Install Camshaft Timing Gear/Sprocket
6. Install Camshaft
7. Install Timing Chain
(1) Camshaft timing sprocket
(2) Camshaft timing gear
(3) Bearing cap
(4) Camshaft
(5) Chain tensioner
(6) Chain tensioner slipper
(7) Chain vibration damper
(8) Timing chain

8. Install Timing Chain Cover

(1)Timing chain cover
(2) Seal packing
(3) O-ring

9. Install Crankshaft Pulley

10. Install Water Pump
11. Install Water Pump Pulley
(1) Crankshaft pulley
(2) Water pump
(3) Gasket
(4) Water pump pulley
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Engine Overhaul>>Reassemble Engine

Components
12. Inspect Valve Clearance
Specified value:
Measurement value:

Intake side

Specified value:
Measurement value:

Exhaust side

13. Adjust Valve Clearance

- Intake side
( A - B ) + T = N

- Exhaust side
( A - B ) + T = N

A: Thickness of new shim (lifter)

B: Thickness of used shim (lifter)
T: Measured valve clearance
N: Specified valve clearance value

14. Install Cylinder Head Cover

(1) Cylinder head cover
(2) Gasket
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Engine Overhaul>>Install Engine

Components

1. Install Intake and Exhaust Manifold, Alternator

(1) Exhaust manifold heat insulator
(2) Exhaust manifold
(3) Exhaust manifold gasket
(4) Manifold support bracket
(5) Intake manifold gasket
(6) Intake manifold
(7) Alternator
(8) Engine wire

2. Remove Engine from Engine Overhaul Stand

(1) Engine
(2) Overhaul stand
(3) Engine sling device
(4) Engine hanger

3. Install Flywheel and Clutch

(1) Flywheel
(2) Clutch disc
(3) Clutch cover

4. Install Transaxle to Engine

(1) Chain block
(2) Engine sling device
(3) Engine
(4) Transaxle
(5) Plate lift attachment

5. Place Engine on Engine Lifter

(1) Chain block
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(2) Engine sling device
(3) Engine
(4) Transaxle
 37/43

Engine Overhaul>>Install Engine

Components
6. Install Engine
7. Install Components from Under Vehicle
(1) Engine lifter
(2) Drive shaft
(3) Tie rod end
(4) Engine
(5) Transaxle
(6) Exhaust pipe
(7) Stabilizer

8. Install Engine Room Components

(1) Shift and select cable
(2) Clutch release cylinder
(3) A/C compressor
(4) Drive belt
(5) Engine mounting
(6) Accelerator cable

9. Connect Fuel Line

(1) Fuel line

10. Connect Clamps and Hoses

(1) Heater hose
(2) Brake booster hose
(3) Air cleaner
(4) Air cleaner hose
(5) Radiator hose
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Engine Overhaul>>Install Engine

Components
11. Install Interior Components
(1) Steering intermediate shaft

12. Connect Connectors and Wire Harness

13. Fill with Coolant
14. Install Battery
(1) Battery

Final Inspection
1. Engine pre-start inspection
(1) Confirm that the connectors are connected to the
positions shown on the tags that were attached during
removal.
(2) Lightly pull each connector and check that it does not
come off.
(3) Make sure that no bolts or nuts are loose.
(4) Check that no components are left on or around the tray
or the working bench.
(5) Check that all clamps are mounted properly in place.
(6) Check that there is no coolant or engine oil leakage
from the hose or pipe connections.
(7) Check that the engine is filled with oil up to the "F" mark
on the oil level gauge.
(8) Check that the drive belt is mounted in the correct
position.
(9) Check that the drive belt tension is appropriate.
(10) Check for abnormal sounds (tapping, scraping) while
the engine is cranking.
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(11) Connect the fuel pump connector, and operate the fuel
pump with intelligent tester to check for fuel leaks.
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Engine Overhaul>>Install Engine

Final Inspection
2. Engine post-start inspection
(1) Start the engine and conduct the following inspections:
<1> Check that the engine starts easily.
<2> Check that no unusual sounds (such as tapping or
scuffing sounds) occur after engine start.
<3> Check that fuel is not leaking.
<4> Check that there is no oil or coolant leakage.
<5> Check that there is no gas leakage.
<6> Check that there is no unusual engine vibration.
(2) Use the tune-up tester and CO/HC tester to check
the engine speed, ignition timing, and exhaust gas
concentration.

3. Coolant inspection
Check the coolant level in the radiator and reservoir.

4. Driving inspection
After bleeding air from the coolant, drive the vehicle and
conduct the following inspections:
(1) When starting the vehicle, check for abnormal noise
around the removed parts.
(2) When accelerating and decelerating, or when the
engine brake is applied check for abnormal noise.

5. Post-driving inspection
Conduct the following inspections to check for
inappropriate installation of components:
(1) Oil quantity and leaks
(2) Fuel leaks
(3) Coolant quantity leaks
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Engine Overhaul>>Install Engine

Final Inspection
6. Vehicle information restoration
(1) Radio stations
(2) Clock
(3) Steering position (with memory system)
(4) Seat position (with memory system)