Engine Disassembly, Inspection & Reassembly: Disassembly

Fig 1: Illustrating Engine-To-Transaxle Disassembly

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1. Remove No. 2 engine mount.
   Fig 2: Removing No. 2 Engine Mount

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2. Remove No. 3 engine mount and bracket.
   Fig 3: Removing No. 3 Engine Mount And Bracket

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3. Remove starter (three bolts).
4. Remove eight transaxle mounting bolts and separate transaxle from engine.
5. Remove exhaust manifold and coolant bypass pipe.
   Fig 4: Removing Exhaust Manifold And Coolant Bypass Pipe

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6. Install engine to Service Tool.
   Fig 5: Installing Engine To Service Tool

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7. Drain engine oil.
8. Remove front and rear engine hangers.
9. Remove generator by loosening adjusting bolt and removing mounting bolts and pivot bolt.
10. Remove intake manifold support bracket.
    Fig 6: Removing Intake Manifold Support Bracket

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11. Remove intake manifold.
    Fig 7: Removing Intake Manifold

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12. For timing belt removal, see TIMING SYSTEM .
13. Loosen cylinder head bolts in two or three steps following order shown in figure.
    Fig 8: Cylinder Head Loosening Sequence

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14. Remove cylinder head by lifting it off from cylinder block.
    Fig 9: Removing Cylinder Head

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15. For additional cylinder head removal and disassembly information, see CYLINDER HEAD ASSEMBLY .
16. Remove external engine components.
    Fig 10: Illustrating External Engine Components

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17. Install SST or equivalent.

    (Clutch disc centering tool and ring gear brake)

18. Loosen each bolt one turn at a time, in a crisscross pattern, until spring tension is released then remove clutch cover and disc.
    Fig 11: Removing Clutch Cover And Disc

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19. Remove pilot bearing with SST (Bearing puller) or equivalent if necessary.
20. Hold flywheel with SST (Ring gear brake) or equivalent.
    Fig 12: Removing Pilot Bearing

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21. Remove six bolts to remove flywheel.
    Fig 13: Removing Flywheel

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22. Remove oil pan mounting bolts.
    Fig 14: Removing Oil Pan Mounting Bolts

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23. Remove oil pan with a screwdriver or suitable tool as shown in figure. See Fig 15.
    CAUTION:

    1. Do not force tools between cylinder block and oil pan as this may damage sealing surface.
    2. Do not damage sealing surface when removing old sealant.
    Fig 15: Removing Oil Pan With A Screwdriver Or Suitable Tool

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24. Remove oil strainer.
    Fig 16: Removing Oil Strainer

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25. Remove timing belt pulley.
    Fig 17: Remove Timing Belt Pulley

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26. Remove oil pump mounting bolt and oil pump.
27. Using a screwdriver covered by a rag, remove oil seal from pump cover side.
    Fig 18: Removing Oil Pump Mounting Bolt And Oil Pump

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28. Remove rear cover.
    Fig 19: Removing Rear Cover

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29. Wrap a prying tool with a shop towel and slowly pry out rear oil seal.
    Fig 20: Prying Out Rear Oil Seal

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30. Remove water pump.
    Fig 21: Removing Water Pump

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31. Remove oil filter and oil pressure switch.
    Fig 22: Removing Oil Filter And Oil Pressure Switch

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    Fig 23: Illustrating Engine Block Components

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32. Check top of each cylinder for ridges.
    NOTE: Failure to remove a ridge before removing piston will result in damaged ring-lands, cracked piston rings, or cracked piston.
33. If a ridge can be felt, use a ridge reamer to remove ridge before attempting to remove piston from cylinder.
    Fig 24: Removing Cylinder Ridge

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34. Rotate engine block so that crankshaft is at Top Dead Center (TDC).
35. Rotate crankshaft so that No. 1 and No. 4 cylinders are at Bottom Dead Center (BDC).
36. Use a numbering stamp and mark rod cap and connecting rod with their corresponding cylinder number.
    NOTE: Mark all rods on same side and make a reference mark on block so that rods are installed in correct position and direction. Failure to install rods properly with result in oil starvation, spun bearings, or damaged internal engine components.
37. Rotate crankshaft so that cylinders No. 2 and No. 3 are at Bottom Dead Center (BDC) and repeat marking procedure.
38. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
39. Remove rod caps.
    NOTE: Cover connecting rod bolts to protect crankshaft journals.
40. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston to release it from cylinder.
41. Repeat this procedure for each cylinder.
    Fig 25: Removing Piston Assemblies

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42. Mark tops of pistons with corresponding cylinder numbers they were removed from.
43. Using a piston ring expander, remove piston rings.
    Fig 26: Removing Piston Rings

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44. Hold piston upright and gently move connecting rod.
45. Release connecting rod and observe its movement.
    NOTE: Do not swing connecting rod wildly. Constant, hard contact with piston will cause a bell-mouth condition that will require piston replacement.
    Fig 27: Measuring Connecting Rod Movement

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46. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and deformation.
47. Remove piston pin clip from ends of piston pin bore.
48. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.
    NOTE: Do not allow pins to drop to the ground.
49. Remove connecting rod from piston. Keep individual piston, piston pin, and piston pin clips together for reassembly.
    Fig 28: Removing Connecting Rod From Piston

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50. Mark main bearing caps (front to back) including direction.
    NOTE: Each main bearing cap is matched to that particular journal. Installing a cap on wrong journal will cause an align bore problem that will require an expensive machine process to correct.
51. Loosen main bearing caps in two or three steps following order shown in figure.
    Fig 29: Main Bearing Caps Loosening Sequence

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52. Remove main bearing caps.
53. Grasp crankshaft and lift straight out.
54. Remove main bearings and thrust bearings from cylinder block saddles.