engine course - English

This chapter explains the parts that make up the engine and explains the work procedure for engine overhaul.

Work Procedures

Chapter Outline

This chapter explains the parts that make up the engine and explains the work procedure for engine overhaul

1 Remove the engine from the vehicle

Remove the engine and transaxle as a unit from the

bottom of the vehicle

2 Disassemble the engine

Disassemble the engine into the cylinder head and block

3 Clean and inspect the parts Inspect all the parts after cleaning them

4 Reassemble the engine Reassemble the cylinder head and block

5 Install the engine in the vehicle Install the engine and transaxle as a unit in the vehicle

6 Final inspection Make a final inspection to check assembly condition

Remove engine

Remove the engine, transaxle, suspension members, etc., as a single unit from under the vehicle

Engine Transaxle Suspension member

Drive shaft Engine lifter Steering gear

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REFERENCE:

When Removing Engine from Top (FR Vehicles)

When removing the engine from the top, remove the engine and transmission as a single unit

The following components need to be removed

(1) Engine hood (2) Radiator (3) Propeller shaft (4) Shift lever

When removing the engine, tilt and turn it while it is slung with the chain block to prevent it from interfering with the vehicle body

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Removal

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

2 Remove Battery (1) Battery

3 Drain Coolant (1) Radiator cap (2) Water drain plug (3) Radiator drain plug

7 Disconnect Fuel Line (1) Fuel line

8 Remove 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 Remove Components from Under Vehicle (1) Drive shaft

(2) Tie rod end (3) Exhaust pipe (4) Stabilizer

(5) Engine lifter

12 Disconnect Transaxle (1) Chain block

(2) Engine sling device (3) Engine

(4) Engine hanger

13 Remove Clutch and Flywheel (1) Flywheel

(2) Clutch disc (3) Clutch cover

14 Install Engine Overhaul Stand (1) Engine

(2) Engine overhaul stand

15 Remove Intake and Exhaust Manifold, Alternator, Engine Wire(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

(1/1)

Intake manifold Auxiliary component (Alternator)

(1/1)

Disassembly

1 Remove Water Pump Pulley (1) Water pump pulley

2 Remove Engine Mounting Bracket (1) Engine mounting bracket

3 Remove Crankshaft Pulley (1) Crankshaft pulley

4 Remove Water Pump (1) Water pump

(2) Gasket

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5 Remove Timing Chain Cover (1) Cylinder head cover

(2) Gasket (3) Timing chain cover

6 Remove Timing Chain (1) Chain tensioner (2) Chain tensioner slipper (3) Chain vibration damper (4) Timing chain

7 Inspect Timing Chain

Vernier calipers Timing chain Spring balance

Pin Bush

8 Remove Camshaft (1) Bearing cap (2) Camshaft

9 Inspect Camshaft Timing Gear

Vane Housing Lock pin Camshaft timing gear

Oil pressure

10 Remove Camshaft Timing Gear/Sprocket (1) Camshaft timing gear (with VVT-i) (2) Camshaft timing sprocket (without VVT-i)

14 Remove Oil Seal (1) Timing chain cover oil seal (2) Engine rear oil seal

Valve stem oil seal Spring seat Valve

3 Remove Valve Stem Oil Seal

Valve stem oil seal Valve spring seat Magnetic handle

4 Clean Cylinder Head

Scraper Oilstone Engine oil

(1/1)

Inspection

1 Inspect Cylinder Head for Flatness

Precision straightedge Thickness gauge

Cylinder block side Intake manifold side Exhaust manifold side

2 Inspect Cylinder Head for Cracks

Crack Cylinder head

3 Inspect Clearance (1) Valve guide bushing oil clearance (2) Valve lifter oil clearance

(3) Camshaft thrust clearance (4) Camshaft oil clearance

Valve guide bushing Valve

Valve lifter

Camshaft Plastigage

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4 Inspect Valve (1) Valve length (2) Valve stem outside diameter (3) Valve head margin thickness

Vernier calipers

5 Inspect Valve Spring (1) Check the free length (2) Check the deviation

Vernier calipers Thickness gauge Steel square

6 Replace Valve Guide Bushing

SST (Valve guide bushing remover and replacer) Valve guide bushing

Heater

7 Inspect Valve Seat

Valve Prussian blue (or white lead) Hand lapper

8 Repair Valve Seat

Seating too high Seating too low Valve seat cut position

9 Inspect Camshaft (1) Check shaft runout (2) Check cam lobe height (3) Check journal diameter

Dial gauge

V - block Micrometer

(1/1)

Valve stem oil seal Spring seat Valve

1 Install Valve Stem Oil Seal

SST (Valve stem oil seal replacer) Valve stem oil seal

Spring seat Apply grease

2 Remove Piston

(1) Piston with connecting rod (2) Bearing

(3) Bearing cap

(1/1)

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3 Remove Crankshaft

(1) Crankshaft (2) Thrust bearing (3) Bearing (4) Bearing cap

4 Disassemble Piston

(1) Piston ring (2) Oil ring (3) Piston (4) Piston pin (5) Connecting rod

(1/1)

Inspection

1 Inspect Cylinder Block for Flatness

Precision straight edge Thickness gauge

2 Inspect Clearance (1) Piston clearance (2) Piston pin clearance (3) Crankshaft oil clearance

Piston Cylinder block Piston pin

Connecting rod Crankshaft bearing cap Crankshaft

3 Inspect Piston and Piston Ring

Thickness gauge New piston ring Clearance of piston ring groove No.1 Clearance of piston ring groove No.2

4 Inspect Bearing Cap Set Bolt

Vernier calipers

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5 Inspect Crankshaft (1) Shaft runout (2) Crankshaft main journal and crank pin diameter check (3) Check timing sprocket wear

Dial gauge

V - block Micrometer

Vernier calipers Crankshaft timing sprocketTiming chain

Crankshaft bearing cap Cylinder block

2 Reassemble Piston

SST (Piston pin remover and replacer)

Piston Piston pin

Connecting rod Piston ring expander Piston ring

Cloth Seal packing

Oil pan No.1 Oil pan No.2

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2 Install Cylinder Head Gasket

Cloth Cylinder head gasket Cylinder block

3 Install Cylinder Head

Cylinder head Cylinder head gasket Cylinder block

Knock pin Cylinder head bolt

4 Install Oil Seal

SST (Oil seal replacer) Oil seal

Cylinder block Timing chain cover

5 Install Camshaft Timing Gear/Sprocket

Knock pin Camshaft timing gear Camshaft

Flange bolt

Aluminium plate Vise

Camshaft timing sprocket

6 Install Camshaft

to is the installation order of the bearing cap

Timing mark

7 Install Timing Chain

Timing chain slipper Chain tensioner

Timing mark Timing chain

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8 Install Timing Chain Cover

Timing chain cover Seal packing O-ring

9 Install Crankshaft Pulley (1) Crankshaft pulley

10 Install Water Pump (1) Water pump (2) Gasket

11 Install Water Pump Pulley (1) Water pump pulley

12 Inspect Valve Clearance

Thickness gauge Timing mark

13 Adjust Valve Clearance

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14 Install Cylinder Head Cover

Cylinder head cover Gasket

When installing Engine from Top (FR Vehicles)

When installing the engine from the top, tilt and turn the engine while installing it in a manner such that it will not interfere with the vehicle body

The following parts must be installed

(1) Propeller shaft (2) Shift lever (3) Radiator (4) Engine hood

(1/1)

Installation

1 Install Intake and Exhaust Manifold, Alternator, Engine Wire (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

5 Place Engine on Engine Lifter (1) Chain block

(2) Engine sling device (3) Engine

(4) Transaxle (5) Engine lifter

6 Install Engine (1) Engine lifter (2) Drive shaft (3) Tie rod end (4) Engine (5) Transaxle

7 Install Components Under Vehicle (1) Drive shaft

(2) Tie rod end (3) Exhaust pipe (4) 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

13 Fill with Coolant (1) Radiator cap (2) Water drain plug (3) Radiator drain plug

14 Install Battery (1) Battery

15 Final Inspection

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