Cylinder block

Repair Procedures

Disassembly

Be careful not to damage parts located under the vehicle (floor under cover, fuel filter, fuel tank, and canister) when lifting the vehicle with a lift. (Refer to General Information - Jack Lifting Points and Support Points)

Use fender covers to avoid damaging painted surfaces. To prevent damage, carefully disconnect the wiring connectors while holding the connector housing.

Label all wires and hoses to avoid incorrect connection. Inspect the timing chain before removing the cylinder head. Turn the crankshaft pulley damper so that the No. 1 piston is at top dead center (TDC).

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. (Refer to Automatic Transaxle System - "Automatic Transaxle")
3. 3
   Remove the drive plate and adapter plate. (Refer to Cylinder Block - "Drive Plate")
4. 4
   Remove the rear oil seal retainer. (Refer to Cylinder Block - "Rear Oil Seal")
5. 5
   Install the engine assembly on an engine stand for disassembly.
6. 6
   Remove the expansion tank. (Refer to Intake and Exhaust System - "Expansion Tank")
7. 7
   Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
8. 8
   Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
9. 9
   Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
10. 10
    Remove the water temperature control unit. (Refer to Cooling System - "Water Temperature Control Assembly")
11. 11
    Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")
12. 12
    Remove the lower oil pan and upper oil pan. (Refer to Lubrication System - "Oil Pan")
13. 13
    Remove the oil pump. (Refer to Lubrication System - "Oil Pump")
14. 14
    Remove the oil filter housing. (Refer to Lubrication System - "Oil Filter Housing").
15. 15
    Remove the oil cap (A) and gasket (B).

    

16. 16
    Remove the water jacket spacer. (Refer to Cylinder Block - "Water Jacket Spacer")
17. 17
    Remove the knock sensor. (Refer to Engine Control/Fuel System - Knock Sensor)
18. 18
    Remove the baffle (A).

    

19. 19
    Check the connecting rod side clearance. (Refer to Cylinder Block - Piston and Connecting Rod)
20. 20
    Check the connecting rod cap oil clearance. (Refer to Cylinder Block – Piston and Connecting Rod)
21. 21
    Remove the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
22. 22
    Remove the crankshaft main bearing cap and check the oil clearance. (Refer to Cylinder Block - Crankshaft)
23. 23
    Check the crankshaft end play. (Refer to Cylinder Block - Crankshaft)
24. 24
    Remove the crankshaft. (Refer to Cylinder Block - Crankshaft)
25. 25
    Remove the oil jets (A).

    

Inspection

1. 1
   Remove the gasket material. Using a gasket scraper, remove all gasket material from the upper surface of the cylinder block.
2. 2
   Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
3. 3
   Inspect the upper surface of the cylinder block for flatness. Using a precision straightedge and feeler gauge, measure the distortion of the surface contacting the cylinder head gasket. Cylinder block gasket surface flatness Standard: Less than 0.05 mm (0.0020 in.) Less than 0.02 mm (0.0008 in.) / 150 x 150

   

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

   Standard diameter: 96.00–96.03 mm (3.7795–3.7807 in)

   

6. 6
   Check the cylinder bore size code on the cylinder block.

   

   Grade	Size code	Cylinder Inner Diameter
   A	A	96.00–96.01 mm (3.7795–3.7799 in)
   B	B	96.01–96.02 mm (3.7799–3.7803 in)
   C	C	96.02–96.03 mm (3.7803–3.7807 in)

Installation

1. 1
   Install the oil jets (A).

   Tightening torque: 27.5–31 N·m

   

2. 2
   Install the crankshaft. (Refer to Cylinder Block - Crankshaft)
3. 3
   Install the crankshaft main bearing cap and check the oil clearance. (Refer to Cylinder Block - Crankshaft)
4. 4
   Check the crankshaft end play. (Refer to Cylinder Block - Crankshaft)
5. 5
   Install the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
6. 6
   Check the connecting rod end play. (Refer to Cylinder Block - Piston and Connecting Rod)
7. 7
   Install the baffle plate. Install and tighten the baffle plate bolts evenly in multiple passes in the sequence shown.

   Tightening torque: 9.8–11.8 N·m

   

8. 8
   Install the knock sensor. (Refer to Engine Control/Fuel System - Knock Sensor)
9. 9
   Install the water jacket separator. (Refer to Cylinder Block - Water Jacket Separator)
10. 10
    Install the oil cap (A) and gasket (B).

    Tightening Torque: 9.8–11.8 N·m

    

11. 11
    Assemble the remaining components in the reverse order of removal.

    After replacing the cylinder block with a new one, select the correct main bearings and piston according to the crankshaft journal bore mark and the cylinder bore mark 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)