RM38N0EC _51 Engine / Hybrid System _111786 M20C-FKS, M20D-FKS ENGINE MECHANICAL _0499725 CYLINDER BLOCK A

M20C-FKS, M20D-FKS ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during cylinder head gasket removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
: Even when not replacing the part, it is necessary to perform the specified necessary procedures afterinstallation. 1: Also necessary after performing a tire rotation. 2: It is not necessary to perform this procedure if the tire pressure warning valve and transmitters areinstalled to the same location. 3: When the starter assembly is replaced, "ST relay" must be also replaced. 4: The vehicle height changes because of suspension or tire replacement. 5: If transaxle compensation code read from ECM *6: If transaxle compensation code not read from ECM
Battery terminal is disconnected/reconnected	Reset back door close position	Power Back Door System	(202111,999999,_59,_111831,_0505274,RM100000001ZMEG,)
Replacement of ECM	Update ECU security key	Vehicle Control History (RoB) are stored	(202111,999999,_V1,_111780,_0504977,RM100000001ZKRX,)
	Perform Vehicle Identification Number (VIN) or frame number registration	DTC is output	(202303,999999,_51,_111785,_0504416,RM1000000029BFA,)
	Code registration	Engine start	See Service Bulletin for the registration method
	· Transfer transaxle compensation code5 · Reset transaxle compensation code6 · CVT oil pressure calibration · Perform road test to allow ECM to learn	· Large shift shock · Deterioration of fuel efficiency	Initialization:(202303,999999,_52,_111806,_0584611,RM1000000029R1M,) Registration:(202303,999999,_52,_111806,_0584611,RM1000000029R1L,)
· Replacement of throttle body with motor assembly · Cleaning the deposits from the throttle body with motor assembly · Replacement of cam timing control motor with EDU assembly* · Replacement of camshaft timing gear assembly* · Replacement of engine assembly · Replacement of cylinder head subassembly · Replacement of camshaft (for intake or exhaust camshaft) · Replacement of camshaft timing exhaust gear assembly · Replacement of port fuel injector assembly · Replacement of direct fuel injector assembly · Replacement of fuel pump assembly (for high pressure side) · Replacement of ignition coil assembly · Replacement of Spark plug · Replacement of EGR valve assembly · Gas leak from exhaust system is repaired	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(202303,999999,_51,_111785,_0504416,RM1000000029BFF,)
Replacement of Starter assembly*3	Clear the number of starteroperations	Stop and Start System	(202111,999999,_51,_111803,_0509671,RM1000000020651,)
Replacement of Battery	Integrated current valueinitialization
· Replacement of Continuously variabletransaxle assembly · Replacement of CVT Fluid	Air bleed the oil pump withmotor assembly
Replacement of continuously variable transaxle assembly	· Input transaxle compensation code into ECM · Perform reset memory · CVT oil pressure calibration · Perform road test to allow ECM to learn	· Large shift shock · Deterioration of fuel efficiency	(202303,999999,_52,_111806,_0584611,RM1000000029R1M,)for K121, K121F Initialization (202303,999999,_52,_111806,_0584611,RM1000000029R1L,)for K121, K121F Registration
Replacement of CVT fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly	(202303,999999,_52,_111806,_0584611,RM1000000029R1M,)
Tires	· Initialization12 · Tire Position Identification12	Tire Pressure Warning System	Refer to Procedures Necessary When Replacing Parts (for Tire Pressure Warning System) table below
Suspension parts*4	Parking assist ECU initialization	Panoramic View Monitor System	(202409,999999,_56,_111825,_0500432,RM100000002O1F6,)
Suspension parts*4	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System	(202409,999999,_56,_111825,_0524148,RM100000002OUWG,)
Front wheel alignment adjustment	· Perform reset memory · Perform "Calibration"	· DTCs are stored · ABS warning light illuminates · Slip indicator light illuminates · Electronically controlled brake system does not operate correctly	(202203,999999,_54,_111814,_0500728,RM1000000022HI0,)
Front bumper assembly*	Front television camera view adjustment	Panoramic View Monitor System	(202409,999999,_56,_111825,_0500432,RM100000002O1F6,)

HINT:

When the cable is disconnected / reconnected to the battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Items for which learning is completed by driving the vehicle
Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Lane Tracing Assist System	Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 seconds or more.	(202111,999999,_95,_111850,_0502173,RM100000001Z92I,)
Pre-collision System		(202111,999999,_95,_111850,_0502173,RM100000001Z92I,)
Stop and Start System	Idle the engine for approximately 5 to 60minutes or drive the vehicle until stop andstart control is permitted	(202406,999999,_51,_111803,_0509671,RM100000002KOGF,)

Items for which learning is completed by operating the vehicle normally
Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Power Door Lock Control System · Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.	(202111,999999,_58,_111830,_0505351,RM100000001ZMT3,)
Air Conditioning System	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

PROCEDURE

Hide Display 12211 1.REMOVE NO. 1 VENTILATION CASE

CAUTION:: Do not disassemble except if the No. 1 ventilation case to be damaged.

Remove the 4 bolts and No. 1 ventilation case from the cylinder block sub-assembly.

Remove the 3 oil separator gaskets from the No. 1 ventilation case.

Hide Display 2.INSPECT CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

Standard Thrust Clearance:: 0.160 to 0.512 mm (0.00630 to 0.0202 in.)

Maximum Thrust Clearance:: 0.512 mm (0.0202 in.)

HINT:: If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

Hide Display 3.INSPECT CONNECTING ROD OIL CLEARANCE

0.708,0.615 0.979,0.26 true 1,0.094 1.302,0.313 0.302,0.219 10 false *a

*a	Alignment Mark

Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.

Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.

HINT:: Keep the connecting rod bearing and connecting rod cap together.

Clean the crank pin and connecting rod bearing.

Check the crank pin and connecting rod bearing for pitting and scratches.

HINT:: If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.

1.635,0.615 0.813,0.458 true 0.635,0.344 0.948,0.563 0.313,0.219 10 false *a

*a	Plastigage

Lay a strip of Plastigage on the crank pin.

1.594,0.698 0.802,0.615 true 0.625,0.5 0.875,0.781 0.25,0.281 10 false *a

*a	Front Mark

Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.

Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

Using an E12 "TORX" socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.

Torque:: 38 N*m (387 kgf*cm, 28 ft.*lbf)

2.26,0.802 2.531,0.385 2.531,0.385 2.677,0.385 false 1.396,0.479 1.854,0.677 0.458,0.198 10 false *b 2.729,0.281 3.042,0.479 0.313,0.198 10 false *a

*a	Paint Mark
*b	90°
	Front of Engine

Mark the front of each connecting rod bolt with paint.

Tighten the connecting rod bolts 90° as shown in the illustration.

NOTICE:: Do not turn the crankshaft during the measurement.

Remove the 2 connecting rod bolts and connecting rod cap.

HINT:: Keep the connecting rod bearing and connecting rod cap together.

1.677,0.969 0.969,0.667 true 1.375,3.167 0.719,3.615 0.719,3.615 1.26,4.208 true 1.385,3.615 0.74,3.615 true 0.802,0.542 1.083,0.708 0.281,0.167 10 false *a 0.542,3.573 0.854,3.729 0.313,0.156 10 false *b

*a	Plastigage
*b	1, 2 or 3 Mark

Measure the Plastigage at its widest point.

Standard Oil Clearance:: 0.032 to 0.065 mm (0.00126 to 0.00256 in.)

Maximum Oil Clearance:: 0.065 mm (0.00256 in.)

HINT:: ·

If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

·

If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

Standard Connecting Rod Big End Inside Diameter:

Mark	Specified Condition
1	51.000 to 51.008 mm (2.00787 to 2.00818 in.)
2	51.008 to 51.016 mm (2.00818 to 2.00850 in.)
3	51.016 to 51.024 mm (2.00850 to 2.00881 in.)

Standard Connecting Rod Bearing Center Wall Thickness:

Mark	Specified Condition
1	1.483 to 1.487 mm (0.05839 to 0.05854 in.)
2	1.487 to 1.491 mm (0.05854 to 0.05870 in.)
3	1.491 to 1.495 mm (0.05870 to 0.05886 in.)

Standard Crank Pin Diameter:: 47.992 to 48.000 mm (1.88945 to 1.88976 in.)

NOTICE:: Remove the Plastigage completely after the measurement.

Perform the inspection above for each cylinder.

Hide Display 4.REMOVE PISTON WITH CONNECTING ROD

1.333,1.094 1.552,1.042 false 1.583,0.938 1.896,1.094 0.313,0.156 10 false *a

*a	Ridge Reamer

Using a ridge reamer, remove all the carbon from the top of each cylinder.

Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.

Push the 4 pistons, 4 connecting rods and 4 connecting rod bearings out through the top of the cylinder block sub-assembly.

HINT:: ·

Keep the connecting rod bearings, connecting rods and connecting rod caps together.

·

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Hide Display 5.REMOVE CONNECTING ROD BEARING

Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

HINT:: Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Hide Display 6.INSPECT CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard Thrust Clearance:: 0.02 to 0.22 mm (0.000787 to 0.00866 in.)

Maximum Thrust Clearance:: 0.22 mm (0.00866 in.)

HINT:: If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.

Standard Thrust Washer Thickness:: 2.415 to 2.470 mm (0.0951 to 0.0972 in.)

Hide Display 13411 7.REMOVE CRANKSHAFT

1.375,1.313 1.531,1.51 0.156,0.198 10 false 1 0.677,0.302 0.833,0.5 0.156,0.198 10 true 4 1.75,0.281 1.948,0.448 0.198,0.167 10 true 10 1.229,0.302 1.385,0.458 0.156,0.156 10 true 8 0.667,1.896 0.823,2.094 0.156,0.198 10 true 3 1.219,1.885 1.375,2.083 0.156,0.198 10 true 7 1.802,1.896 1.958,2.094 0.156,0.198 10 true 9 2.354,1.885 2.51,2.083 0.156,0.198 10 true 5 2.917,1.896 3.073,2.063 0.156,0.167 10 true 1 2.917,0.313 3.073,0.49 0.156,0.177 10 true 2 2.354,0.313 2.531,0.469 0.177,0.156 10 true 6

Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

HINT:: ·

Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.

·

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the crankshaft from the cylinder block sub-assembly.

HINT:: Keep the No. 1 crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

Check each crankshaft journal and crankshaft bearing for pitting and scratches.

If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

Hide Display 11791 8.REMOVE CRANKSHAFT THRUST WASHER

Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.

Hide Display 9.REMOVE CRANKSHAFT BEARING

Remove the 5 No. 1 crankshaft bearings and 5 No. 2 crankshaft bearings from the cylinder block sub-assembly and 5 crankshaft bearing caps.

HINT:: Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Hide Display 13011 10.REMOVE PISTON RING SET

1.115,1.76 1.115,1.531 1.115,1.531 1.354,1.281 false 1.063,1.802 1.375,2 0.313,0.198 10 false *a

*a	Piston Ring Expander

Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.

Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

HINT:: Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Hide Display 13101A 11.REMOVE PISTON PIN HOLE SNAP RING

1.885,0.979 2.208,1.188 true 2.104,0.813 2.313,0.375 true 2.25,1.115 2.563,1.271 0.313,0.156 10 false *a 2.344,0.271 2.656,0.427 0.313,0.156 10 false *b

*a	Front Mark Cutout Portion
*b	Protective Tape

Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.

HINT:: Tape the screwdriver tip before use.

Hide Display 12.REMOVE PISTON

Gradually heat each piston to between 80 and 90°C (176 and 194°F).

CAUTION:: Be sure to wear protective gloves.

Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.

HINT:: ·

The piston and piston pin are a matched set.

·

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Hide Display 15708 13.REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.

Hide Display 15709 14.REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY

Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.