Cylinder Block Repair Procedures

Disassembly

Use fender covers to avoid damaging painted surfaces. To prevent damage to the cylinder head, wait until the engine coolant temperature drops below normal temperature (20 °C [68°F]) before removing it. When handling the metal gasket, be careful not to bend the gasket or damage the gasket contact surface. To avoid damage, carefully disconnect the wiring connectors by holding the connector body.

Label all wires and hoses to avoid incorrect connection. Turn the crankshaft pulley so that the No. 1 piston is at TDC (top dead center).

1. 1
   Remove the engine assembly from the vehicle. (Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2. 2
   Remove the transaxle assembly from the engine assembly. Automatic Transaxle (Refer to Automatic Transaxle System - "Automatic Transaxle")
3. 3
   Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")
4. 4
   Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")
5. 5
   Install the engine on an engine stand for disassembly.
6. 6
   Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
7. 7
   Remove the water pump assembly. (Refer to Cooling System - "Water Pump")
8. 8
   Remove the water inlet hose and thermostat assembly. (Refer to Cooling System - "Electric Thermostat (ECT)")
9. 9
   Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
10. 10
    Remove the A/C compressor. (Refer to Heating, Ventilation and Air Conditioning - "Compressor")
11. 11
    Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
12. 12
    Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")
13. 13
    Remove the oil filter. (Refer to Lubrication System - "Engine Oil")
14. 14
    Remove the oil screen. (Refer to Lubrication System - "Oil Pan")
15. 15
    Remove the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
16. 16
    Remove the crankshaft. (Refer to Cylinder Block - Crankshaft)
17. 17
    Remove the knock sensor (KS). (Refer to Engine Control/Fuel System - Knock Sensor (KS)).
18. 18
    Remove the crankshaft position sensor (CKPS). (Refer to Engine Control/Fuel System - Crankshaft Position Sensor (CKPS)).
19. 19
    Remove the oil pressure switch. (Refer to Lubrication System - Oil Pressure Switch)

Inspection

1. 1
   Remove the gasket material. Using a gasket scraper, remove all gasket material from the cylinder block upper surface.
2. 2
   Clean the Cylinder Block. Using a soft brush and solvent, thoroughly clean the cylinder block.
3. 3
   Inspect the cylinder block upper surface for flatness. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head gasket for distortion. Cylinder block gasket surface flatness Standard: Overall less than 0.05 mm (0.0020 in.) Less than 0.02 mm (0.0008 in.) for a 100 mm (3.9370 in.) x 100 mm (3.9370 in.) section

   

4. 4
   Inspect the cylinder bore. Visually check the cylinder for vertical scratches. If deep scratches are found, replace the cylinder block.
5. 5
   Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at the positions in the axial and thrust directions.

   Cylinder bore diameter: 81.00 - 81.03 mm (3.1890 - 3.1902 in.)

   

   Measure at the positions (from the top of the cylinder block): 10 mm (0.3937 in.) / 71 mm (2.7953 in.) / 131.5 mm (5.1772 in.)

Installation

1. Assemble the remaining components in the reverse order of removal.

If replacing the cylinder block with a new one, select the correct crankshaft main bearing and piston according to the crankshaft journal bore mark and the cylinder bore mark stamped on the cylinder block. Selection of Crankshaft Main Bearing (Refer to Cylinder Block - Crankshaft) Selection of Piston (Refer to Cylinder Block - Piston and Connecting Rod)