Installation
Cylinder BlockCylinder Block Components:
INSTALLATION
1) After setting the cylinder block to ST, install the crankshaft bearing.
ST 18232AA000 ENGINE STAND
NOTE:
Apply a coat of engine oil to the bearing and crankshaft journal.
2) Mount the crankshaft in cylinder block (LH).
3) Apply liquid gasket to the mating surfaces of cylinder block (RH).
CAUTION:
Do not allow liquid gasket to run over into oil passages, bearing grooves, etc.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
4) Attach cylinder block (RH) to cylinder block (LH).
5) Apply a coat of engine oil to the washer and bolt thread.
6) Tighten all bolts in the numerical order as shown in the figure.
7) Retighten all bolts in the numerical order as shown in the figure.
8) Tighten all bolts by 90 degrees in numerical order as shown in the figure.
9) Install the upper bolt to cylinder block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Remove any liquid gasket squeezed out onto the seal surface between the chain cover and oil pan upper, after tightening the cylinder block connecting bolts.
10) Apply a coat of engine oil to the oil seal periphery and install the rear oil seal using ST1 and ST2.
NOTE:
Use a new rear oil seal.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
11) Face the front of the engine up, standing the engine on one end.
12) Attach the piston ring and oil ring to the piston.
1) Position the top ring gap at (A) in the figure.
2) Position the second ring gap at (B).
3) Position the upper rail gap at (C) in the figure.
4) Position the expander gap at (D) in the figure.
5) Position the lower rail gap at (E) in the figure.
CAUTION:
^ Make sure ring gaps do not face the same direction.
^ Make sure ring gaps are not within the piston skirt area.
^ Assemble so that the stamp mark N faces towards the top of the piston.
13) Install the #1 piston and connecting rod to the cylinder block.
1) Apply engine oil to the outer circumference of the piston and in the cylinder block.
2) Face the front mark of piston (A) towards the front of the engine, and set the piston to the ST.
3) Using ST, press-fit the piston into cylinder block.
NOTE:
When inserting the piston into the cylinder block, perform according to the items listed below.
^ Insert while lightly tapping the top of the piston with the handle of a plastic hammer.
^ Insert while making sure that the large end of the connecting rod does not scratch the cylinder liner.
^ Insert while continually making sure that the large end of the connecting rod does not touch the crankshaft.
ST 398744300 PISTON GUIDE
4) Using the ST, turn the crankshaft and match the positions of the crank pin and the large end of the connecting rod.
ST 18252AA000 CRANKSHAFT SOCKET
5) Install the connecting rod cap.
14) In the same procedures as for the #1 piston, install the piston and connecting rods to the cylinder block, in the order of #2, #3, #4, #5 and #6.
15) Install the O-ring to the underside of the cylinder block.
NOTE:
Use new O-rings.
16) Apply liquid gasket to the mating surface of oil pan upper.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
17) Temporarily tighten the oil pan upper.
18) Tighten the oil pan upper installing bolts in the numerical order as shown in the figure.
19) Install the thermostat and thermostat cover.
20) Install the oil level switch.
21) Install the oil pump.
22) Tighten the oil cooler connector to install the oil cooler to the oil pan upper.
Tightening torque:
54 Nm (5.5 kgf-m, 39.8 ft-lb)
NOTE:
Use new O-rings.
23) Apply liquid gasket to the matching surface of oil pan lower.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
24) Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.
25) Install the crankshaft position sensor plate.
26) Install the crankshaft position sensor.
27) Using the ST, install the drive plate.
ST 498497100 CRANKSHAFT STOPPER
28) Install the cylinder head.
29) Install the camshaft.
30) Install the crank sprocket.
31) Install the cam sprocket.
32) Install the timing chain assembly.
33) Install the chain cover.
34) Install the crank pulley.
35) Install the engine to the vehicle.
DISASSEMBLY
NOTE:
To prevent confusion of various parts, mark each part.
1) Remove the connecting rod bearing.
2) Remove the piston rings using piston ring expander.
3) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order, to prevent confusion.
4) Remove the snap ring.
5) Using snap ring pliers, remove the snap ring.
6) Remove the piston pin from the piston.
7) Separate the piston and connecting rod.
NOTE:
Mark the direction of front side to each connecting rod.
8) Remove the plug and orifice from the cylinder block as necessary.
ASSEMBLY
1) Apply engine oil to the surface of the connecting rod bearing. Attach the connecting rod bearing to the connecting rod.
2) Join the connecting rod and piston.
NOTE:
Position each connecting rod with the marked side facing forward.
3) Apply engine oil to the piston pin, and attach the piston pin.
4) Using snap ring pliers, attach the snap ring.
5) Install the oil ring upper rail, expander and lower rail by hand.
6) Install the second ring and top ring using piston ring expander.
INSPECTION
CYLINDER BLOCK
1) Visually check for cracks or damage. Use liquid penetrant tester on the important sections.
2) Check the oil passages for clogging.
3) Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge. If the warpage exceeds limit, replace the cylinder block.
Warping limit:
0.020 mm (0.0008 in)
Standard height of cylinder block:
202 mm (7.95 in)
CYLINDER AND PISTON
1) The cylinder bore size is stamped on the front upper face of the cylinder block.
NOTE:
^ Measurement should be performed at a temperature of 20 degrees C (68 degrees F).
^ Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston.
2) Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge.
NOTE:
Measurement should be performed at a temperature of 20 degrees C (68 degrees F).
3) When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance.
4) Measure outer diameter of each piston. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction)
NOTE:
Measurement should be performed at a temperature of 20 degrees C (68 degrees F).
Piston grade point H:
37.3 mm (1.4685 in)
5) Calculate the clearance between cylinder and piston.
NOTE:
Measurement should be performed at a temperature of 20 degrees C (68 degrees F).
Cylinder to piston clearance at 20 degrees C (68 degrees F):
Standard
-0.010 - 0.010 mm (-0.0004 - 0.0004 in)
6) Boring and honing:
1) If any of the measured value of taper, out-of-roundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons.
NOTE:
Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature.
Cylinder inner diameter boring limit (diameter):
To 92.515 mm (3.6717 in)
PISTON AND PISTON PIN
1) Check the piston and piston pin for damage, cracks or wear. And check the piston ring groove for wear or damage. Replace if faulty.
2) Measure the clearance between piston and cylinder in each cylinder.If the clearance exceeds the standard, replace the piston, or rebore the cylinder so that an oversize piston can be used.
3) Make sure the piston pin can be inserted into the piston pin hole by a thumb at 20 degrees C (68 degrees F). Replace if faulty.
4) Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
5) Check the piston pin snap ring for distortion, cracks and wear.
PISTON RING
1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston.
NOTE:
^ The top ring and second ring have the mark to determine the direction for installing. When attaching the ring to the piston, face these marks towards the top side.
^ Oil ring consists of the upper rail, expander and lower rail. When installing to the piston, be careful of the direction of each rail.
2) Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
3) Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge.
NOTE:
Before measuring the clearance, clean the piston ring groove and piston ring.
CONNECTING ROD
1) Replace the connecting rod, if the large or small end thrust surface is damaged.
2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist.
3) Install the connecting rod with bearings attached to the crankshaft, and using a thickness gauge, measure the thrust clearance. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod.
4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on each connecting rod bearing using Plastigage(R). If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the table below.)
6) Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged.
7) Measure the piston pin clearance at connecting rod small end. Replace it with a new part if the value is not within the standard.
8) The replacement procedure for the connecting rod small end bushing is as follows.
1) Remove the bushing from connecting rod with ST and press.
2) Apply oil on the periphery of the new bushing, and press the bushing in with the ST.
ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER
3) Make two 3 mm (0.12 in) holes in the pressed bushing to match the pre-manufactured holes on the connecting rod, then ream the inside of the bushing.
4) After completion of reaming, clean the bushing to remove chips.
CRANKSHAFT AND CRANKSHAFT BEARING
1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft.
2) Check the crankshaft for bend, and repair or replace if needed. If it exceeds the limit, correct or replace it.
NOTE:
If a suitable V-block is not available, using the #1 and #7 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge.
3) Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used.
4) Use a thickness gauge to measure the thrust clearance of crankshaft at center bearing. If clearance exceeds the standard, replace the bearing.
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
6) Measure the oil clearance on each crankshaft bearing using Plastigage(R). If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary.
Crankshaft oil clearance:
Standard
0.010 - 0.030 mm (0.0004 - 0.0012 in)