NOTE:
Before conducting this procedure, drain the engine oil completely.
1. Remove the V-belts. 
2. Remove the intake manifold.
3. Remove the crank pulley.
4. Remove the timing belt cover.
5. Remove the timing belt.
6. Remove the cam sprocket.
7. Remove the crank sprocket.
8. Remove the generator and A/C compressor with their brackets.
9. Remove the camshaft.
10. Remove the cylinder head.
11. Remove the clutch disc and cover. (MT model)
12. Remove the flywheel. (MT model)
13. Remove the drive plate. (AT model)
14. Remove the oil separator cover.
15. Remove the water by-pass pipe for heater.
16. Remove the oil filter.
17. Remove the water pump.
18. Remove the bolts which install oil pump onto cylinder block.
NOTE:
When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
19. Remove the oil pump from cylinder block using a flat tip screwdriver.
CAUTION:
Be careful not to scratch the mating surface of cylinder block and oil pump.
20. Remove the front oil seal from the oil pump.
21. Remove the oil pan.
(1) Set the part so that the cylinder block LH is on the upper side.
(2) Remove the bolts which secure oil pan to cylinder block.
(3) Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.
CAUTION:
Do not use a screwdriver or similar tools in place of oil pan cutter.
22. Remove the oil strainer.
23. Remove the baffle plate.
24. Remove the water tank pipe assembly.
25. Remove the water pipe assembly.
|
(1) |
Service hole plug |
(4) |
Piston pin |
(7) |
Seal washer |
|
(2) |
Gasket |
(5) |
Service hole cover |
(8) |
Washer |
|
(3) |
Snap ring |
(6) |
O-ring |
26. Remove the service hole plugs using a hexagon wrench [14 mm].
27. Remove the service hole cover.
28. 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.
29. Draw out the piston pin from #1 and #2 pistons using ST.
| ST 499097700 | PISTON PIN REMOVER |
NOTE:
Be careful not to confuse the original combination of piston, piston pin and cylinder.
30. Similarly remove the piston pins from #3 and #4 pistons.
31. Remove the cylinder block connecting bolt on the RH side.
32. Loosen the cylinder block connecting bolt on the LH side by 2-3 turns.
33. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
34. Separate cylinder block LH and RH.
NOTE:
When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
|
(1) |
Cylinder block |
(4) |
Crankshaft bearing |
(7) |
Washer |
|
(2) |
Rear oil seal |
(5) |
Piston |
||
|
(3) |
Crankshaft |
(6) |
Seal washer |
35. Remove the rear oil seal.
36. Remove the crankshaft together with connecting rod.
37. Remove the crankshaft bearings from cylinder block using a hammer handle.
NOTE:
• Push the opposite side of the crank shaft bearing locking lip to remove.
• Be careful not to confuse the crankshaft bearing combination.
38. Draw out each piston from cylinder block using wooden bar or hammer handle.
NOTE:
Be careful not to confuse the original combination of piston and cylinder.