Before VIN 343314

Cylinder Block

CAUTION:
^ When installing sliding parts such as bearings and pistons, be sure to apply engine oil on the sliding surfaces.
^ Place removed parts such as bearings and bearing caps in their proper order and direction.
^ When installing connecting rod bolts and main bearing cap bolts, apply new engine oil to threads and seating surfaces.
^ Do not allow any magnetic materials to contact the ring gear teeth on flywheel or drive plate and rear plate.

Disassembly
PISTON AND CRANKSHAFT





1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove oil pan and oil pump.
4. Remove timing belt.
5. Remove water pump.
6. Remove cylinder head.





7. Remove pistons with connecting rods.
^ When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature.

CAUTION:
^ When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
^ When replacing piston rings, if there is no punchmark, install with either side up.





8. Remove bearing cap and crankshaft.
^ Before removing bearing cap, measure crankshaft end play.
^ Bolts should be loosened in two or three steps.

Inspection
PISTON AND PISTON PIN CLEARANCE





1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp": 20.969 - 20.981 mm (0.8255 - 0.8260 inch)





2. Measure outer diameter of piston pin "Dp".
Standard diameter "Dp": 20.971 - 20.983 mm (0.8256 - 0.8261 inch)
3. Calculate piston pin clearance.
dp - Dp = 0 - 0.004 mm (0 - 0.0002 inch)
If it exceeds the above value, replace piston assembly with pin.





PISTON RING SIDE CLEARANCE
Side clearance:
Top ring: 0.024 - 0.076 mm (0.0009 - 0.0030 inch)
2nd ring: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Max. limit of side clearance:
Top ring: 0.11 mm (0.0043 inch)
2nd ring: 0.1 mm (0.004 inch)
If out of specification, replace piston and/or piston ring assembly.





PISTON RING END GAP
End gap:
Top ring: 0.21 - 0.40 mm (0.0083 - 0.0157 inch)
2nd ring: 0.50 - 0.69 mm (0.0197 - 0.0272 inch)
Oil ring: 0.20 - 0.69 mm (0.0079 - 0.0272 inch)
Max. limit of ring gap:
Top ring: 0.54 mm (0.0213 inch)
2nd ring: 0.80 mm (0.0315 inch)
Oil ring: 0.95 mm (0.0374 inch)
If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, rebore cylinder and use oversized piston and piston rings.
Refer to Engine; Specifications.
^ When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION





Bend:
Limit: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) length





Torsion:
Limit: 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length
If it exceeds the limit, replace connecting rod assembly.

CYLINDER BLOCK DISTORTION AND WEAR





1. Clean upper face of cylinder block and measure the distortion.
Limit: 0.10 mm (0.0039 inch)
2. If out of specification, resurface it.
The resurfacing limit is determined by cylinder head resurfacing in engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "B".
The maximum limit is as follows: A + B = 0.2 mm (0.008 inch)
Nominal cylinder block height from crankshaft center: 227.60 - 227.70 mm (8.9606 - 8.9645 inch)
If necessary, replace cylinder block.

PISTON-TO-BORE CLEARANCE





1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper.
Standard inner diameter: 91.500 - 91.530 mm (3.6024 - 3.6035 inch)
Refer to "CYLINDER BLOCK" at Engine; Specifications.
Wear limit: 0.20 mm (0.0079 inch)





If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
Out-of-round (X - Y) standard: 0.015 mm (0.0006 inch)
Taper (A - B or A - C) standard: 0.015 mm (0.0006 inch)
2. Check for scratches and seizure. If seizure is found, hone it.








^ If both cylinder block and piston are replaced with new ones, select piston of the same grade number according to the following table. These numbers are punched on cylinder block and piston in either Arabic or Roman numerals.





Combination of grade number for cylinder bore and piston





3. Measure piston skirt diameter.
Piston diameter "A":
Refer to Engine; Specifications.
Measuring point "a" (Distance from the top): 49.0 mm (1.929 inch)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.015 - 0.025 mm (0.0006 - 0.0010 inch) for No. 3 and 4 cylinders
0.025 - 0.045 mm (0.0010 - 0.0018 inch) except for No. 3 and 4 cylinders
5. Determine piston oversize according to amount of cylinder wear.
Oversize pistons are available for service. Refer to Engine; Specifications.
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A".
Rebored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance: 0.02 mm (0.0008 inch)
7. Install main bearing caps, and tighten to the specified torque to prevent distortion of cylinder bores in final assembly.
8. Cut cylinder bores.
^ When any cylinder needs boring, all other cylinders must also be bored.
^ Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 inch) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
^ Measurement should be done after cylinder bore cools down.

CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or cracks.





2. With a micrometer, measure journals for taper and out-of-round.
Out-of-round (X - Y): Less than 0.005 mm (0.0002 inch)
Taper (A - B): Less than 0.005 mm (0.0002 inch)





3. Measure crankshaft runout.
Runout (Total indicator reading): Less than 0.10 mm (0.0039 inch)

BEARING CLEARANCE
^ Either of the following two methods may be used, however, method A gives more reliable results and is preferable.

Method A (Using bore gauge & micrometer)

Main bearing





1. Set main bearings in their proper positions on cylinder block and main bearing cap.
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order in two or three stages.





3. Measure inner diameter "A" of each main bearing.





4. Measure outer diameter "Dm" of each crankshaft main journal.
5. Calculate main bearing clearance.
Main bearing clearance (A - Dm):
Standard: 0.028 - 0.055 mm (0.0011 - 0.0022 inch)
Limit: 0.090 mm (0.0035 inch)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.





a. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 inch)
b. Refer to Engine; Specifications for grinding crankshaft and available service parts.
8. If crankshaft is reused, measure main bearing clearances and select thickness of main bearings.
If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows:





a. Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals.





b. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the following example or table.





Main bearing grade number
No. 1 main bearing (Identification color):





No. 2, 3 and No. 4 main bearings (Identification color):

Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.





3. Measure inner diameter "C" of each bearing.





4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance (C - Dp):
Standard: 0.014 - 0.054 mm (0.0006 - 0.0021 inch)
Limit: 0.090 mm (0.0035 inch)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to step 7 of "BEARING CLEARANCE-Main bearing".

Method B (Using plastigage)





CAUTION:
^ Do not turn crankshaft or connecting rod while plastigage is being inserted.
^ When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.

CONNECTING ROD BUSHING CLEARANCE (Small end)





1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C - Dp
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
Limit: 0.023 mm (0.0009 inch)
If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.

REPLACEMENT OF CONNECTING ROD BUSHING (Small end)





1. Drive in small end bushing until it is flush with end surface of rod.
Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing so that clearance between connecting rod bushing and piston pin is the specified value.
Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 inch)

FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Flywheel (M/T model): Less than 0.15 mm (0.0059 inch)
Drive plate (A/T model): Less than 0.15 mm (0.0059 inch)





CAUTION:
^ Be careful not to damage the ring gear teeth.
^ Check the drive plate for deformation or cracks.
^ Do not allow any magnetic materials to contact the ring gear teeth.
^ Do not surface flywheel. Replace as necessary.

Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.





2. Heat piston to 60 to 70°C (140 to 1 58°F) and assemble piston, piston pin, connecting rod and new snap ring.
^ Align the direction of piston and connecting rod.
^ Numbers stamped on connecting rod and cap correspond to each cylinder.
^ After assembly, make sure connecting rod swings smoothly.





3. Set piston rings as shown.

CRANKSHAFT





1. Set main bearings in their proper positions on cylinder block and main bearing cap
^ Confirm that correct main bearings are used.
Refer to "Inspection".





2. Install crankshaft and main bearing caps and tighten bolts to the specified torque.
^ Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction.
^ Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially.
^ After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
^ Lubricate threads and seat surfaces of the bolts with new engine oil.





3. Measure crankshaft end play.
Crankshaft end play:
Standard: 0.050 - 0.170 mm (0.0020 - 0.0067 inch)
Limit: 0.30 mm (0.0118 inch)
If beyond the limit, replace bearing with a new one.





4. Install connecting rod bearings in connecting rods and connecting rod caps.
^ Confirm that correct bearings are used.
Refer to "Inspection".
^ Install bearings so that oil hole in connecting rod aligns with oil hole of bearing.
5. Install pistons with connecting rods.





a. Install them into corresponding cylinders with Tool.
^ Be careful not to scratch cylinder wall by connecting rod.
^ Arrange so that front mark on piston head faces toward front of engine.





b. Install connecting rod bearing caps.
^ Lubricate threads and seat surfaces with new engine oil. Tighten connecting rod bearing cap nuts to the specified torque.
: Connecting rod bearing nut
(1) Tighten to 14 to 16 Nm (1.4 to 1.6 kfg-m, 10 to 12 ft. lbs.).
(2) Turn nuts 60 to 65 degrees clockwise.
If an angle wrench is not available, tighten nuts to 38 to 44 Nm (3.9 to 4.5 kfg-m, 28 to 33 ft. lbs.).





6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit: 0.40 mm (0.0157 inch)
If beyond the limit, replace connecting rod and/or crankshaft.





7. Install rear oil seal retainer.

REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)





1. Remove pilot bushing (M/T) or pilot converter (A/T).





2. Install pilot bushing (M/T) or pilot converter (A/T).