Disassembly and Assembly

CAUTION: When installing sliding parts (bearings, pistons, etc.), lubricate contacting surfaces with new engine oil.
Place removed parts such as bearings and bearing caps in their proper order and direction.
When installing connecting rod nuts 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 of flywheel or drive plate.









Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove timing belt.
4. Remove oil pan and oil pump.
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.







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)


Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70°C (140 to 158°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.







Assembly
CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block and main bearing cap.
Confirm that correct main bearings are used. Apply new engine oil to bearing surfaces.






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 "Connecting Rod Bearing (Big End)".
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 kg-m, 10 to 12 ft. lbs.).
(2).....Tighten 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 kg-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).