Disassembly
ENGINE UNITCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
DISASSEMBLY
1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
6. REMOVE CYLINDER HEAD COVER GASKET
7. REMOVE OIL FILTER SUB-ASSEMBLY
8. REMOVE OIL FILTER UNION
(a) Using a 12 mm socket hexagon wrench, remove the oil filter union.
9. REMOVE CAMSHAFT POSITION SENSOR
10. REMOVE CRANKSHAFT POSITION SENSOR
11. REMOVE WATER PUMP PULLEY
12. REMOVE WATER PUMP ASSEMBLY
13. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket.
14. REMOVE OIL PAN SUB-ASSEMBLY
15. REMOVE CRANKSHAFT PULLEY
16. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
17. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
18. REMOVE TIMING CHAIN COVER OIL SEAL
19. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
20. REMOVE TIMING CHAIN GUIDE
21. REMOVE CHAIN TENSIONER SLIPPER
22. REMOVE CHAIN SUB-ASSEMBLY
23. REMOVE NO. 1 CHAIN VIBRATION DAMPER
24. REMOVE CRANKSHAFT TIMING SPROCKET
25. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
26. REMOVE OIL PUMP DRIVE GEAR
27. REMOVE OIL PUMP ASSEMBLY
28. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
29. REMOVE CYLINDER HEAD SUB-ASSEMBLY
30. REMOVE CYLINDER HEAD GASKET
31. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
32. REMOVE OIL CONTROL VALVE FILTER
(a) Using a 6 mm socket hexagon wrench, remove the plug and gasket.
(b) Remove the oil control valve filter.
33. REMOVE NO. 1 TAPER SCREW PLUG
(a) Remove the plug from the cylinder block.
34. INSPECT BALANCE SHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance: 0.09 mm (0.0035 in.)
If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.
35. INSPECT BALANCE SHAFT OIL CLEARANCE
(a) Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.
(b) Remove the balance shaft housing from the crankcase.
HINT: Keep the lower bearing and balance shaft housing together.
(c) Lift out the No. 1 and No. 2 balance shafts.
HINT: Keep the upper bearing with the crankcase.
(d) Clean each bearing and journal.
(e) Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
(f) Place the No. 1 and No. 2 balance shafts onto the crankcase.
(g) Lay a strip of Plastigage across each journal.
(h) Install the balance shaft housing.
(i) Apply a light coat of engine oil on the threads and under the heads of the bolts.
(j) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 21.6 N*m (220 kgf*cm, 16 ft.*lbf)
(k) Mark the front of the bolts with paint.
(l) Retighten the bolts 90° as shown in the illustration.
(m) Check that the paint mark is now at a 90° angle to the front.
(n) Remove the balance shaft housing from the crankcase.
(o) Measure the Plastigage at its widest point.
Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 in.)
Maximum oil clearance: 0.049 mm (0.0019 in.)
NOTICE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft.
HINT: If replacing a bearing, select a new one with the same number.
Standard Balance Shaft Housing Journal Bore Diameter:
Standard balance shaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Standard bearing center wall thickness:
36. REMOVE BALANCE SHAFT
37. REMOVE NO. 1 BALANCE SHAFT BEARING
38. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the lip of the oil seal.
(b) Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
NOTICE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
39. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
(b) Remove the crankcase by prying the portions between the crankcase and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder bock.
(c) Remove the O-ring from the cylinder block.
40. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod. If necessary, replace the crankshaft.
41. INSPECT CONNECTING ROD OIL CLEARANCE
NOTICE: Do not turn the crankshaft during the measurement.
(a) Using marking paint, write the matched cylinder number on each connecting rod and cap.
HINT: The matchmarks in the connecting rods and caps are for ensuring correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage on the crank pin.
(f) Check that the front mark of the connecting rod cap is facing in the correct direction.
(g) Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
(h) Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
(i) Mark the front of the connecting rod bolts with paint.
(j) Retighten the cap bolts 90° as shown in the illustration.
(k) Check that the crankshaft turns smoothly.
(l) Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
(m) Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance: 0.08 mm (0.0032 in.)
NOTICE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft.
HINT: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
Standard Connecting Rod Large End Bore Diameter:
Standard Connecting Rod Bearing Thickness:
Standard crankshaft pin diameter:
42. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
^ Keep the bearing, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in the correct order.
43. REMOVE CONNECTING ROD BEARING
44. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and expander by hand.
45. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
46. REMOVE PISTON
(a) Gradually heat the piston up to 80 to 90°C (176 to 194°F).
(b) Using a plastic hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod.
HINT:
^ The piston and pin are a matched set.
^ Arrange the piston, pin, ring, connecting rod and bearings in the correct order.
47. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).
48. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE: Do not turn the crankshaft during the measurement.
(a) Clean each main journal and bearing.
(b) Check each main journal and bearing for pitting and scratches.
(c) Install the upper bearing with an oil groove onto the cylinder block.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
(d) Install the lower bearing onto the bearing cap.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
(e) Place the crankshaft onto the cylinder block.
(f) Lay a strip of Plastigage across each journal.
(g) Examine the front marks and numbers and install the bearing caps onto the cylinder block in the order shown in the illustration.
(h) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
(i) Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
(j) Mark the front of the bearing cap bolts with paint.
(k) Retighten the 10 bearing cap bolts by 90°.
(l) Check that the paint marks are at a 90° angle to the front.
(m) Remove the bearing caps.
(n) Measure the Plastigage at its widest point.
Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 in.)
Maximum oil clearance: 0.050 mm (0.0020 in.)
NOTICE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.
HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
EXAMPLE
^ Imprinted number on the cylinder block is 3.
^ Imprinted number on the crankshaft is 4. 3 + 4 = 7
Select the bearing marked "7".
Standard cylinder block journal bore diameter:
Standard crankshaft journal diameter (Part 1):
Standard crankshaft journal diameter (Part 2):
Standard bearing center wall thickness:
49. REMOVE CRANKSHAFT
(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 5 bearing caps from the cylinder block.
(c) Remove the crankshaft from the cylinder block.
50. REMOVE CRANKSHAFT THRUST WASHER UPPER
51. REMOVE CRANKSHAFT BEARING
HINT: Arrange the bearings in the correct order.
52. REMOVE NO. 2 CRANKSHAFT BEARING
HINT: Arrange the bearings in the correct order.
53. REMOVE STUD BOLT
(a) Remove the 8 stud bolts.
INSPECTION
1. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace the cylinder block.
2. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter: 88.500 to 88.513 mm (3.4843 to 3.4848 in.)
Maximum diameter: 88.633 mm (3.4895 in.)
If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.
3. INSPECT PISTON
(a) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 30.3 mm (1.193 in.) from the piston head.
Standard piston diameter: 88.439 to 88.449 mm (3.4819 to 3.4822 in.)
If the diameter is not as specified, replace the piston.
4. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.051 to 0.074 mm (0.0020 to 0.0029 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
5. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between the new piston ring and wall of the ring groove.
Standard ring groove clearance:
If the groove clearance is not as specified, replace the piston.
6. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
Maximum end gap:
If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, replace the cylinder block.
7. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the piston pin bore diameter.
Standard piston pin bore diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.)
If the diameter is not as specified, replace the piston.
(b) Using a micrometer, measure the piston pin diameter.
Standard piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.)
If the diameter is not as specified, replace the piston pin.
(c) Using a caliper gauge, measure the connecting rod small end bore diameter.
Standard connecting rod small end bore diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.)
If the diameter is not as specified, replace the connecting rod.
(d) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.0003 in.)
Maximum oil clearance: 0.013 mm (0.0005 in.)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
(e) Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.017 mm (0.0007 in.)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
8. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the misalignment is greater than the maximum, replace the connecting rod.
(2) Check for twist.
Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod.
9. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Maximum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the connecting rod bolt.
10. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 in.)
If the taper and distortion are greater than the maximum, replace the crankshaft.
(b) Using a micrometer, measure the diameter of each main journal.
Standard diameter: 54.998 to 55.000 mm (2.1649 to 2.1654 in.)
If the diameter is not as specified, check the crankshaft oil clearance.
(c) Check each main journal for taper and distortion as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 in.)
If the taper and distortion are greater than the maximum, replace the crankshaft.
Standard diameter (Reference):
(d) Using a micrometer, measure the diameter of each crank pin.
Standard diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.)
If the diameter is not as specified, check the connecting rod oil clearance.
(e) Inspect each crank pin for taper and distortion as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 in.)
f the taper and distortion are greater than the maximum, replace the crankshaft.
11. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.5 mm (0.295 in.)
If the diameter is less than the minimum, replace the bolt.