Repair Procedures

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.

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).

5. Remove the upper oil pan(A).

CAUTION:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of 1 arrow.
- After tapping the SST with a plastic hammer along the direction of 2 arrows around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It be result in damage of the SST.

6. Check the connecting rod side clearance.
7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies.

NOTE:
- Keep the bearings the connecting rods and the caps together.
- 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)

INSPECTION

CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth.

Specification
Standard : 0.1 - 0.25mm(0.0039 - 0.0098in.)
Limit : 0.4mm(0.0157in.)

A. If out-of-tolerance, install a new connecting rod.
B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and the lower bearing.
(4) Clean the crankshaft pin journal and the bearing.
(5) Place a plastigage across the crankshaft pin.
(6) Reinstall the lower bearing and the connecting rod cap and torque the bolts.

Tightening torque
17.7 - 21.6Nm (1.8 - 2.2kgf.m, 13.0 - 15.9lb-ft) + 90 - 94°

NOTE:
Do not turn the crankshaft.

(7) Remove the connecting rod cap again.
(8) Measure the plastigage at its widest point.

Standard oil clearance
0.018 - 0.036mm(0.0007 - 0.0014in.)

(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.

CAUTION:
Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.

NOTE:
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

CAUTION:
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

CONNECTING ROD MARK LOCATION

DISCRIMINATION OF CONNECTING ROD

CRANKSHAFT PIN MARK LOCATION

DISCRIMINATION OF CRANKSHAFT

DISCRIMINATION OF CRANKSHAFT

PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING)

DISCRIMINATION OF CONNECTING ROD BEARING

(11) Select the proper connecting rod bearing from the table below.

3. Check the connecting rod.
(1) When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction.
(2) If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it.
(3) Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with a press. If the rod is bent or twisted excessily, replace it.

Bending : 0.05mm/100mm(0.0020in./3.9370in.)
Torsion : 0.1mm/100mm(0.0039in./3.9370in.)

NOTE:
When assembling the rod without a bearing, there should be no difference.

4. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.

Tightening torque
M8 : 12.7 - 18.6Nm (1.3 - 1.9kgf.m, 9.4 - 13.7lb-ft) + 90 - 95°
M10 : 26.5 - 32.4Nm (2.7 - 3.3kgf.m, 19.5 - 23.9lb-ft) + 90 - 95°

NOTE:
Tighten the bolts in order.

(5) Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance
0.004 - 0.022mm (0.0002 - 0.0009in.)

(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.

CAUTION:
Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.

NOTE:
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

CAUTION:
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

Crankshaft bore mark location
Letters have been stamped on the block as a mark for the each size of the 4 main journal bores.
No.1 journal stamping mark starts from the front of the engine.
Use the size marks which are stamped on the block and the crankshaft for the journal bore inner diameter and the journal outer diameter to choose the correct bearings.

DISCRIMINATION OF CYLINDER BLOCK

CRANKSHAFT JOURNAL MARK LOCATION

DISCRIMINATION OF CRANKSHAFT

DISCRIMINATION OF CRANKSHAFT

PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)

DISCRIMINATION OF CRANKSHAFT BEARING

SELECTION TABLE

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

Standard end play
0.07 - 0.25mm (0.0028 - 0.0098in.)
[Limit]
0.3mm(0.0118in.)

If the end play is greater than the maximum, replace the center bearing.

Thrust bearing thickness
1.925 - 1.965mm(0.0758 - 0.0774in.)

6. Inspect the main journals and the pin journals of the crankshaft.
7. Using a micrometer, measure the outer diameter of each main journal and pin journal.

Main journal diameter : 61.982 - 62.000mm (2.4402 - 2.4409in.)
Crank pin diameter : 47.982 - 48.000mm (1.8891 - 1.8898in.)

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 diameter
86.70 - 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.

Specification
0.02 - 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 13.5 mm (0.5315 in) from the bottom of the piston.

Standard diameter
86.67 - 86.70(3.4122 - 3.4134in.)

3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.

Piston-to-cylinder clearance
0.02 - 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 outerdiameter
21.001 - 21.007mm (0.8268 - 0.8270in.)

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance
0.011 - 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:
- Thoroughly clean all parts before reassembling.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
- 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 : 12.7 - 18.6Nm (1.3 - 1.9kgf.m, 9.4 - 13.7lb-ft) + 90 - 95°
M10 : 26.5 - 32.4Nm (2.7 - 3.3kgf.m, 19.5 - 23.9lb-ft) + 90 - 95°

NOTE:
- Use new main bearing cap bolt with engine oil applied.
- If any of the bearing cap bolts are broken or deformed, replace it.
- Washers have their direction(Up/Down)
- Assemble the bearing cap bridge on which its arrow mark faces the engine front.
- 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:
- Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
- 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
17.7 - 21.6Nm (1.8 - 2.2kgf.m, 13.0 - 15.9lb-ft) + 90 - 94°

NOTE:
- Always use new connecting rod bolts.
- Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.

- 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) Clean the sealing surface face before assembling the two parts.

NOTE:
- Remove harmful foreign materials on the sealing face before applying sealant
- 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:
- Clean the sealing face before assembling two parts.
- Remove harmful foreign materials on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not protrude into the inside of oil pan.
- 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:
- Clean the sealing face before assembling two parts.
- Remove harmful foreign materials on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not protrude into the inside of oil pan.
- 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:
- On Bank 1, the black knock sensor connector should be installed and on Bank 2, the gray one should.

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)