Cylinder Block Assembly: Service and Repair
DISASSEMBLY
PISTON AND CRANKSHAFT
1. Place engine on work stand.
2. Drain coolant and oil.
3. Remove timing belt.
4. Remove water pump.
5. Remove oil pan and oil pump.
6. Remove cylinder head.
7. Remove pistons.
8. Remove bearing caps and crankshaft.
Note: Place the bearings and caps in their proper order.
Upper bearings (cylinder block side) have oil groove.
INSPECTION
PISTON AND PISTON PIN CLEARANCE
Confirm the fitting of piston pin into piston pin hole to such an extent that it can be pressed smoothly by finger at room temperature.
Piston pin to piston clearance:
0.003 - 0.017 mm (0.0001 - 0.0007 in)
Note: Apply engine oil to piston pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.040 - 0.073 mm (0.0016 - 0.0029 in)
2nd ring
0.030 - 0.063 mm (0.0012 - 0.0025 in)
Max. limit of side clearance (Top and 2nd rings):
0.1 mm (0.004 in)
PISTON RING GAP
Standard ring gap mm (in):
Top ring
0.25-0.51(0.0098 - 0.0201)
2nd ring
0.25-0.51(0.0098 - 0.0201)
Oil ring (Rail ring)
0.20-0.76 (0.0079 - 0.0299)
Max. limit of ring gap:
1.0 mm (0.039 in)
Note: If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, rebore the cylinder and use oversize piston/piston ring assembly.
BEARING CLEARANCE
Bearing clearance:
Main bearing
0.020 - 0.047 mm (0.0008 - 0.0019 in)
Limit 0.1 mm (0.004 in)
Connecting rod bearing
0.010 - 0.044 mm (0.0004 - 0.0017 in)
Limit 0.1 mm (0.004 in)
MAIN BEARING
1. Install main bearings to cylinder block and main bearing cap.
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order and in two or three stages. 44 - 54 N.m (4.5 - 5.5 kg-m, 33 - 40 ft-lb).
3. Measure inside diameter "A" of main journal.
4. Measure outside diameter "Dm" of main journal in crank- shaft.
5. Calculate main bearing clearance.
Main bearing clearance = A - Dm
Standard: 0.020 - 0.047 mm (0.0008 - 0.0019 in)
Limit: 0.1 mm (0.004 in)
Note: If it exceeds the limit, replace the bearing. If it still exceeds the limit even with a new bearing, regrind crank journal and use undersized bearings.
CONNECTING ROD BEARING CLEARANCE (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Note: Apply oil to the thread portion of bolts and seating surface of nuts.
Tighten: 32 - 36 N.m (3.3 - 3.7 kg-m, 24 - 27 ft-lb)
3. Measure inside diameter "C" of bearing.
4. Measure outside diameter "Dp" of crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard: 0.010 - 0.044 mm (0.0004 - 0.0017 in)
Limit: 0.1 mm (0.004 in)
Note: If it exceeds the limit, replace the bearing. If it still exceeds the limit even with a new bearing, regrind crank pin and use undersized bearings.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in) per 100 mm (3.94 in) length
CRANKSHAFT
1. Check crankshaft journals for score, bias, wear or cracks. If faults are minor, correct with fine crocus cloth.
2. Check journals with a micrometer for taper and out-of-round.
Out-of-round (X - Less than 0.005 mm (0.0002 in)
Taper (A - B):
Less than 0.005 mm (0.0002 in) Limit: 0.03 mm (0.0012 in)
a. When regrinding crank pin and crank journal, measure "L" dimension in fillet roll. Make sure the measurements exceed the specified limit. If the measurements are less than the specified limit, do not regrind.
L1: More than 0.10 mm (0.0039 in)
b. Fillet roll should not be reground.
L2:
Pin journal
2.5 mm (0.098 in)
Main journal
2.0 mm (0.079 in)
3. Check crankshaft runout.
Runout [T.I.R. (Total Indicator Reading)]:
Less than 0.1 mm (0.004 in)
CYLINDER BLOCK DISTORTION AND WEAR
Clean upper face of cylinder block and measure the distortion.
Limit:
0.10 mm (0.0039 in)
Note: If out of specification, resurface it.
The resurfacing limit of cylinder block is determined by the cylinder head resurfacing in an 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 in)
CYLINDER BORE
1. Using a bore gauge, measure cylinder bore for wear, out-of-round or taper.
Standard inside diameter:
84.50-84.55 mm (3.3268 - 3.3287 in)
Wear limit
0.20 mm (0.0079 in)
Out-of-round (X - Y) limit
0.015 mm (0.0006 in)
Taper (A - B) limit
0.010 mm (0.0004 in)
Note: If it exceeds the limit, rebore all four cylinders. Replace cylinder block if necessary. Check for scratches or seizure. If seizure is found, hone it.
^ If both cylinder block and pistons are replaced with new ones, select piston of the same grade number punched on the cylinder block upper surface.
2. The size to which cylinders must be honed is determined by adding piston-to-cylinder clearance to the piston skirt diameter "A".
Dimension "a":
Approximately 20 mm (0.79 in) Rebored size calculation
D = A + B - C = A + [0.005 to 0.025 mm (0.0002 to 0.0010 in)]
where,
D : Honed diameter
A : Skirt diameter as measured
B : Piston-to-wall clearance
C : Machining allowance
0.02 mm (0.0008 in)
3. Install main bearing caps in place, and tighten to the specified torque to prevent distortion of the cylinder bores in final assembly.
4. Cut cylinder bores in the order of 2-4-1-3.
Caution: Do not cut too much out of the cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
5. Hone the cylinders to the required size.
6. Measure the finished cylinder bore for out-of-round and taper.
Caution: Measurement of a just-machined cylinder bore requires utmost care since it is expanded by cutting heat.
PISTON TO CYLINDER WALL CLEARANCE
Using micrometer
1. Measure piston and cylinder bore diameter.
Piston diameter "A":
Refer to Specifications.
Measuring point "a" (Distance from the bottom):
Approximately 20 mm (0.79 in)
2. Check that piston clearance is within the specification.
Piston clearance:
0.025 - 0.045 mm (0.0010 - 0.0018 in) Using feeler gauge
Measure the extracting force by pulling feeler gauge straight upward.
Feeler gauge thickness:
0.04 mm (0.0016 in)
Extracting force:
2.0 - 14.7 N (0.2 - 1.5 kg, 0.4 - 3.3 lb).
FLYWHEEL RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in).
ASSEMBLY
PISTON
a. Numbers stamped on the connecting rod and cap correspond to each cylinder. Care should be taken to avoid a wrong combination including bearing.
b. When pressing piston pin in connecting rod, apply engine oil to pin and small end of connecting rod.
c. After assembling, ascertain that piston swings smoothly.
1. Install piston rings.
CRANKSHAFT
1. Set main bearings in the proper position on cylinder block.
Note: If either crankshaft, cylinder block or main bearing is reused again, it is necessary to measure main bearing clearance.
Upper bearings (Cylinder block side) have oil groove.
2. Apply engine oil to main bearing surfaces on both sides of cylinder block and cap.
3. Install crankshaft and main bearing caps and tighten bolts to specified torque.
Main bearing cap bolt:
Tighten: 44-54 N.m (4.5 - 5.5 kg-m, 33 - 40 ft-lb)
^ Arrange the parts so that the indicated number on bearing cap is in a row from the front of engine.
^ Prior to tightening bearing cap bolts, place bearing cap in proper position by shifting crankshaft in the axial direction.
^ Tighten bearing cap bolts gradually in separating two or three stages and outwardly from center bearing in sequence.
^ After securing bearing cap bolts, make sure that crankshaft turns smoothly.
4. Measure crankshaft free end play at center bearing.
Crankshaft free end play:
Limit
0.30 mm (0.0118 in)
Note: Set piston ring as shown.
5. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
Caution: Be careful not to scratch cylinder wall by connecting rod.
Note:
Apply engine oil to cylinder wall, piston and bearing.
Arrange so that the front mark on piston head faces to the front of engine.
(2) Install connecting rod bearing caps.
Tighten in two or three stages.
Connecting rod bearing nut:
Tighten: 32-36 N.m (3.3 - 3.7 kg-m, 24 - 27 ft-lb)
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Limit 0.30 mm (0.0118 in)
REPLACING PILOT BUSHING
1. Remove pilot bushing (M/T) or pilot convertor (A/T).
2. Install pilot bushing (M/T) or pilot convertor (A/T).