Cylinder Block
COMPONENTS
REMOVAL
1. Remove the drive plate(A).
2. Remove the rear plate(A).
3. Remove timing belt.
4. Remove intake manifold.
5. Remove exhaust manifold.
6. Remove generator from engine.
7. Remove power steering pump from engine.
8. Remove cylinder head.
9. Remove A/C compressor from engine.
10. Remove water pump assembly.
INSTALLATION
1. Install the water pump.
2. Install the air conditioning compressor.
3. Install the cylinder head.
4. Install the power steering pump.
5. Install the generator.
6. Install the intake manifold.
7. Install the exhaust manifold.
8. Install the timing belt.
9. Install the rear plate(A).
Tightening torque: 9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
10. Install the drive plate(A).
Tightening torque: 71.6 - 75.5Nm (7.3 - 7.7kgf.m, 52.8 - 55.7lb-ft)
DISASSEMBLY
1. Remove the power steering pump bracket(A) and the knock sensor(B).
2. Remove the air conditioning compressor bracket(A).
3. Remove the lower oil pan(A).
CAUTION:
When removing the oil pan, use the SST(09215-3C000) not to damage the contacting surface of the oil pan.
4. Remove the oil screen(A).
5. Remove the upper oil pan(A).
CAUTION:
When removing the oil pan, use the SST(09215-3C000) not to damage the contacting surface of the oil pan.
6. Check the connecting rod side clearance.
7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies.
NOTE:
a. Keep the bearings the connecting rods and the caps together.
b. Arrange the piston and connecting rod assemblies in the correct order.
9. Remove the oil pump case.
10. Remove the oil seal case(A).
11. Check the crankshaft end play.
12. Remove the crankshaft bearing cap and check oil clearance.
NOTE:
Arrange the bearings and the bearing caps in order.
13. Lift the crankshaft(A) out of the block, being careful not to damage journals.
14. Remove and arrange the main bearings and thrust bearings in the correct order.
15. Remove the CKP sensor(A).
16. Check the free play between a piston and a piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston pin as a set.
17. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove the 2 side rails and the oil ring by hand.
NOTE:
Arrange the piston rings in the correct order only.
18. Disconnect the connecting rod from the piston.
Using a press, remove the piston pin from the piston.
(Press-in load : 2451.7 - 12258.3N(250 - 1250kg, 551.2 - 2755.81lb)
CYLINDER BLOCK
1. Remove gasket materials.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface Standard : 0.03mm (0.0012in.) or less
4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block or process the piston to be oversized.
5. Inspect the cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter86.70 - 86.73mm (3.4134 - 3.4146in.)
6. Check the cylinder bore size code(A) on the cylinder block.
7. Check the piston size code(A) on the piston top face.
8. Select the proper piston related to the cylinder bore class.
Clearance : 0.02 - 0.04mm (0.0008 - 0.0016in.)
CYLINDER BORING
1. The over size piston is chosen on the maximum inner diameter of the cylinder.
NOTE:
The piston size mark is on the top surface of the piston.
2. Measure the outer diameter of the piston which is installed before.
3. Calculate the new bore size with the measurement in the step 2.
New bore size = measured outer diameter of piston + 0.02 - 0.04mm (0.0008-0.0016in.)[clearance] - 0.01mm (0.0004in.)[for horning]
4. Bore the cylinder to the calculated size.
CAUTION:
Bore the cylinders in firing order to prevent the cylinders from be twisted by high temperature.
5. Stop boring and start horning for the proper clearance.
6. Measure the clearance between a piston and a cylinder.
Specification0.02 - 0.04mm (0.0008 - 0.0016in.)
NOTE:
Bore all the cylinders with the same over size.
PISTON AND RINGS
1. Clean pistons.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
NOTE:
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of the piston.
Standard diameter86.67 - 87.00(3.4122 - 3.4252in.)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance0.02 - 0.04mm (0.0008 - 0.0016in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between a new piston ring and the ring groove.
Piston ring side clearance Standard No.1 : 0.04 - 0.08mm (0.0016 - 0.0031in.) / No.2 : 0.03 - 0.07mm (0.0012 - 0.0027in.) / Oil ring : 0.06 - 0.15mm (0.0024 - 0.0059in.) / Limit No.1 : 0.1mm (0.004in.) / No.2 : 0.1mm (0.004in.) / Oil ring : 0.2mm (0.008in.)
If the clearance is greater than the maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is over the service limit, the cylinder block must be replaced or bored
Piston ring end gap Standard No.1 : 0.15 - 0.30mm (0.0059 - 0.0118in.) / No.2 : 0.30 - 0.45m (0.0118 - 0.0177in.) / Oil ring : 0.20 - 0.70mm (0.0079 - 0.0275in.) / Limit No.1 : 0.6mm (0.0236in.) / No.2 : 0.7mm (0.0275in.) / Oil ring : 0.8mm (0.0315in.)
PISTON PINS
1. Measure the outer diameter of the piston pin.
Piston pin outerdiameter21.001 - 21.007mm (0.8268 - 0.8270in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance0.011 - 0.018mm (0.0004 - 0.0007in.)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference-0.033 - -0.016mm (-0.0013 - -0.0006in.)
REASSEMBLY
NOTE:
a. Thoroughly clean all parts before reassembling.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
c. Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and the connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark(A) and the connecting rod front mark must face the timing belt side of the engine.
2. Install piston rings.
(1) Install the oil ring spacer and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings.
(1) Align the bearing(A) claw with the groove of the connecting rod or connecting rod cap(B).
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
CAUTION:
When reassembling the connecting rods and the caps, ensure the front marks on them.
4. Install the CKP sensor(A).
Tightening torque: 6.9 - 9.8Nm (0.7 - 1.0kgf.m, 5.1 - 7.2lb-ft)
5. Install main bearings.
NOTE:
Upper bearings have the oil grooves of the oil holes; Lower bearings do not.
(1) Aligning the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings(A).
(2) Aligning the bearing claw with the claw groove of the main bearing cap, push in the 4 lower bearings(B) on the bearing caps(A).
6. Install thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
7. Place crankshaft(A) on the cylinder block.
8. Place main bearing caps on cylinder block.
9. Install main bearing cap bolts.
(1) Install and uniformly tighten the bearing cap bolts, in two steps, in the sequence shown.
Tightening torque: M8 : 15.7Nm (1.6 kgf.m, 11.6lb-ft) + 90°M10 : 29.4Nm (3.0 kgf.m, 21.7lb-ft)+ 90°
NOTE:
a. Use new main bearing cap bolt with engine oil applied.
b. If any of the bearing cap bolts are broken or deformed, replace it.
c. Washers have their direction(Up/Down)
d. Assemble the bearing cap bridge on which its arrow mark faces the engine front.
e. Before tightening, make the bearing caps be seated on the block firmly.
NOTE:
Use SST( 09221-4A000 ), install main bearing cap bolts.
(2) Check that the crankshaft turns smoothly.
10. Check crankshaft end play.
11. Install the piston and connecting rod assemblies.
NOTE:
a. Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
b. When installing the piston, ensure that the coat on the cylinder wall is not damaged or scratched.
(1) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
(2) Stop inserting the piston when the ring inserted in the cylinder and check the alignment of the journal and the connecting rod.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque: 19.6Nm (2.0kgf.m, 14.46lb-ft) + 90°
NOTE:
a. Always use new connecting rod bolts.
b. Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
c. Use SST(09221-4A000), install connecting rod bearing cap bolts.
12. Install the rear oil seal case.
Tightening torque: 9.80 - 11.76Nm (1.0 - 1.2kgf.m, 7.23 - 8.67lb-ft)
(1) Make clean the sealing face before assembling two parts.
NOTE:
a. Remove harmful foreign materials on the sealing face before applying sealant
b. Apply sealant to the inner threads of the bolt holes.
(2) Assembling rear oil seal case, the liquid sealant TB1217H should be applied to the rear oil seal case.
The part must be assembled within 5 minutes after sealant was applied.
13. Using SST(09231-33000), install rear oil seal after applying engine oil on the rip of the oil seal.
14. Install the oil pump case.
15. Install upper oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
NOTE:
a. Clean the sealing face before assembling two parts.
b. Remove harmful foreign materials on the sealing face before applying sealant.
c. When applying sealant gasket, sealant must not protrude into the inside of oil pan.
d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
(3) Install upper oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque: Bolts 1-15 : 18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft) / Bolts 16,17 : 4.9 - 6.9Nm (0.5 - 0.7kgf.m, 3.6 - 5.1lb-ft)
16. Install the oil screen(A).
Tightening torque: 14.7 - 21.6Nm (1.5 - 2.2kgf.m, 10.8 - 15.9lb-ft)
17. Install the lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on lower oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
NOTE:
a. Clean the sealing face before assembling two parts.
b. Remove harmful foreign materials on the sealing face before applying sealant.
c. When applying sealant gasket, sealant must not protrude into the inside of oil pan.
d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
(3) Install lower oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque: 9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
18. Install the air conditioning compressor bracket(A).
19. Install the power steering pump bracket(A) and the knock sensor(B).
Tightening torque: 18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
CAUTION:
a. On Bank 1, the black knock sensor connector should be installed and on Bank 2, the gray one should.