Top of exhaust manifold and adjacent parts on SR20DE engine
1 - injection valve; 2 - O-ring, always replace; 3 - O-ring, always replace; 4 - bolt, 3-4 Nm; 5 - rubber gasket; 6 - nut, 18-21 Nm; 7 - bolt, 20-25 Nm; 8 - bolt, 18-22 Nm; 9 - throttle actuator drum; 10 - rubber gasket; 11 - the upper part of the exhaust manifold; 12 - manifold gasket; 13 - bolt, 6-8 Nm; 14 - gasket; 15 - nut, 18-21 Nm
The lower part of the intake manifold and adjacent parts
1 - intake manifold support; 2 - bolt, 16-21 Nm; 3 - throttle body; 4 - bolt, 16-21 Nm; 5 - intake manifold support; 6 - the lower part of the intake manifold; 7 - vacuum hoses; 8 - gasket; 9 - transistor; 10 - bolt, 16-21 Nm; 11 - intake manifold support; 12 - air regulator; 13 - additional air valve; 14 - bolt, 6-8 Nm; 15 - intake manifold support; 16 - bolt, 16-21 Nm; 17 - bolt, 6-8 N·m
1. Before disassembling the engine, thoroughly clean all external surfaces to remove dirt or oil. Particular attention must be paid to the sealing surfaces so that foreign objects cannot enter the motor when the sealing surfaces are separated. Fix the engine on the mounting stand. If there is no stand, place the engine on a workbench supported on the side with wooden blocks so that it does not fall. In the following description, the general disassembly process is first described. The individual construct groups will then be described separately.
2. If a manual transmission is installed, loosen the clutch bolts evenly and crosswise. Turn out the bolts completely only after the tension of the clutch diaphragm spring has been relieved. Remove the clutch, remove the driven plate from the flywheel and set aside the parts. If the driven disc looks satisfactory, do not touch it with dirty hands.
3. If an automatic transmission is installed, remove the torque converter. These activities are described in Chapter automatic transmission.
4. Turn the engine over and remove the oil drain plug on the underside of the oil pan.
5. Unscrew the oil filter with a special wrench. If there is no special key, drive a powerful screwdriver into the filter from the side and, using its handle as a lever, unscrew the filter. Discard the filter immediately.
6. Disconnect the ignition cables and remove the distributor cap with cables (open the spring clips on the cover).
7. Turn the crankshaft until the piston of the 1st cylinder is in the TDC position of the end of the cycle. To do this, turn the crankshaft by plugging the opening of the spark plug of the 1st cylinder with your thumb (unscrew the spark plug). When the finger feels pressure, and the mark on the crankshaft pulley will be in the position shown in the illustration, i.e. opposite the mark «0», the position of the crankshaft is correct.
The piston of the 1st cylinder is in the TDC position, if the mark "0" coincides with the tip of the pointer.
8. Using a scriber, draw a line on the outer edge of the ignition distributor opposite the tip of the slider. When installing, the distributor must be set to this position.
9. Loosen the ignition distributor bolt and remove it.
10. Unscrew the remaining spark plugs.
11. Unscrew fuel lines, vacuum pipes and other additional elements from the engine.
12. Unscrew the cylinder head cover and oil deflector.
13. Unscrew the exhaust manifold supports. The SR20DE engine has 4 mounts, the SR20Di engine has one mount.
14. Unscrew an inlet pipe and the details which are nearby. On the SR20DE engine, the intake manifold consists of two parts, on which are shown in the illustrations Top of exhaust manifold and adjacent parts on SR20DE engine and The lower part of the intake manifold and adjacent parts details. Unscrew the parts until both parts of the pipeline can be separated and unscrew from the engine. Remove any loose gaskets. The SR20Di engine uses a one-piece intake manifold. The throttle body is screwed onto the intake manifold and can be unscrewed beforehand. Near the pipeline are various parts that can also be unscrewed.
15. On the other side of the engine, unscrew the exhaust manifold cover and then remove the manifold. On this side of the engine, also remove the alternator suspension bracket, the alternator drive belt tensioning bracket, the compressor console (if installed), cooling system outlet housing and oil dipstick.
16. On a carbureted engine, unscrew the intake manifold with the carburetor and set aside. Label the individual hoses connected to the carburetor before disconnecting them. The exhaust gas composition control valve and the fuel pump are also on this side. Unscrew the exhaust manifold after removing the heat shield. Loosen and remove the three fittings screwed into the intake manifold. The lambda probe is also screwed into the manifold.
17. Remove the chain drive and camshafts as described in Section Cylinder head and timing gear. This operation also includes the removal of the crankshaft belt pulley.
18. Next, the cylinder head is removed. Since this work is close to removing the drive chain, they are described together in Section Compression test. It should already be noted that the cylinder head bolts must be of a certain length in order to be used again.
19. This should be remembered when removing and installing the cylinder head. Before carrying out the following work, mark the installation position of the pistons, connecting rods, bearings and bearing caps. Cylinder number can be scratched on the pistons (not too deep). Mark the connecting rods and bearing caps either with a punch, or lay out all the parts on the workbench so as not to confuse them.
20. Unscrew the oil pan. At the same time, turn the engine so that the pallet is at the bottom. Oil deposits must not get inside the engine.
21. Unscrew the screen of the suction pipe. As you can see, the injection engine sump consists of two parts, however, for disassembly of the engine, it can be removed as a single unit. In chapter Engine lubrication system - general information a more detailed description of this work is given.
22. Hold the hammer handle between the crankshaft and the crankcase wall and loosen the flywheel bolts one by one. Knock down the flywheel with a rubber mallet, making sure it does not fall. If an automatic transmission is installed, remove the torque converter drive disc in the same way.
23. Rotate the crankshaft until all pistons are about halfway up and carefully scrape off the oil combustion products on the top side of the cylinders with a scraper without damaging the bores.
24. Place a large container under the engine and collect the remaining oil and coolant in the block.
25. Unscrew from the block of cylinders a back cover and remove a lining.
26. Unscrew the connecting rod bearing caps one by one. Tap the cover lightly with a rubber mallet and remove the cover with the inserts. Typically, caps and connecting rods are numbered 1 to 4, but be sure to check if these designations are present.
27. Push the pistons with connecting rods from the bottom of the cylinders. To facilitate removal, the two pistons must be in the BDC position. After that, immediately fasten the covers with liners to the corresponding connecting rods.
28. Remove the crankshaft. Crankshaft bearings are different for injection and carburetor engines. Shaft removal is described in detail for both versions in Section Crankshaft and crankshaft bearings.