Crankshaft and Cylinder Block
CRANKSHAFT AND CYLINDER BLOCKREMOVAL AND INSTALLATION
CAUTION
Do not remove the block heater unless it is damaged, because it cannot be re-used once it is removed.
Removal Steps 1-16:
Required Special Tool:
^ MD998718: Crankshaft Rear Oil Seal Installer
INSTALLATION SERVICE POINTS
[A] BLOCK HEATER INSTALLATION
Within 30 degrees of the center, install the block heater as shown in Fig.
[B] KNOCK SENSOR BRACKET INSTALLATION
Check that the bracket is in proper contact with the cylinder block boss and tighten to the specified torque in the order shown.
Tightening torque: 28 ± 2 Nm (21 ± 1 ft-lb)
[C] CRANKSHAFT BEARING INSTALLATION
1. Measure the crankshaft journal diameter and confirm its classification from the following table. In the case of a crankshaft supplied as a service part, identification colors/marks of its journals are painted/stamped at the positions shown in the illustration.
2. The cylinder block bearing bore diameter identification marks are stamped at the position shown in the illustration from left to right, beginning at No.1.
3. From the above table, select a bearing whose size is appropriate for the crankshaft journal outside diameter. If the crankshaft journal outside diameter ID color is "yellow" and the cylinder block bearing bore ID mark is "III," for example, select a bearing whose ID color is "green" [No.1, 4] or "red" [No.2, 3].
If there is no ID color paint on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the measured valve.
4. Install bearings with the groove toward the cylinder block.
5. Install the bearings having no groove to the bearing cap.
[D] CRANKSHAFT THRUST BEARING INSTALLATION
1. Install the thrust bearing in the No.3 bearing bore in the cylinder block and in the bearing cap. For easier installation, apply engine oil to the bearings; this will help hold them in position.
2. The thrust bearings must be installed with their groove toward the crankshaft web.
[E] BEARING CAP / BEARING CAP BOLT INSTALLATION
1. Attach the bearing cap on the cylinder block as shown in the illustration.
2. Tighten the bearing cap bolts to specified torque in the sequence shown in the illustration.
Tightening torque: 74 ± 4 Nm (54 ± 3 ft-lb)
3. Check that the crankshaft rotates smoothly.
4. Check the end play. If it exceeds the limit value, replace the thrust bearing.
Standard value: 0.05 - 0.25 mm (0.002 - 0.009 inch)
Limit: 0.3 mm (0.01 inch)
[F] CRANKSHAFT REAR OIL SEAL INSTALLATION
Using special tool MD998718, press-fit a new crankshaft rear oil seal into the oil seal case.
[G] OIL SEAL CASE INSTALLATION
1. Apply the sealant (Three bond 1217G or exact equivalent) to the oil seal case.
2. Apply a small amount of engine oil to the entire circumference of the oil seal lip section, and place the oil seal case on the cylinder block.
NOTE: Install the oil seal case within 15 minutes after applying liquid gasket. Then wait at least one hour. Do not start the engine or let engine oil or coolant touch the sealant during that time.
INSPECTION
CRANKSHAFT JOURNAL OIL CLEARANCE [PLASTIGAGE METHOD]
1. Remove oil from the crankshaft journal and crankshaft bearing inner surface.
2. Install the crankshaft.
3. Cut plastigage to the same length as the width of the bearing and place it on the journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
Tightening torque: 74 ± 4 Nm (54 ± 3 ft-lb)
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastigage at its widest section by using a scale printed on the plastigage bag.
Standard value:
0.018 - 0.036 mm (0.0007 - 0.0014 inch) [No.1, 4]
0.024 - 0.042 mm (0.0009 - 0.0017 inch) [No.2, 3]
Limit: 0.1 mm (0.003 inch)
CRANKSHAFT REAR OIL SEAL
1. Check the oil seal lip for wear and damage.
2. Check the rubber for deterioration or hardening.
3. Check the oil seal case for cracks and damage.
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use a flaw detecting agent for the check. If defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable limit or replace.
Grinding limit: *0.2 mm (0.008 inch)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
227.9 - 228.1 mm (8.972 - 8.980 inches)
4. Check the cylinder walls for scratches and seizure. If defects are evident, correct (bored to an oversize) or replace.
5. Using a cylinder gauge, measure the cylinder bore and cylindricality. If worn badly, correct by boring the cylinders to an oversize and replace pistons and piston rings. Measure at the points shown in the illustration.
Standard value:
Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
BORING CYLINDER
1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder.
2. Measure the outside diameter of the piston to be used. Measure it in the thrust direction as shown.
3. Based on the measured piston Outside Diameter (OD), calculate the boring finish dimension.
Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin)
CAUTION
To prevent distortion that may result from temperature rise during honing, bore cylinders in the order of number 2, number 4, number 6, number 1, number 3 and number 5.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
Standard value:
Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.02 - 0.04 mm (0.0008 - 0.0015 inch)
NOTE: When boring cylinders, finish all six cylinders to the same oversize. Do not bore only one cylinder to an oversize.