Cylinder Block Assembly: Service and Repair

Note:
Arrange the disassembled parts on the parts stand in accordance with their assembled locations, sequence, etc., so that the parts will be reassembled in their original locations. Place mating marks on the parts if necessary.

CYLINDER BLOCK
1. Visually check cylinder block for cracks or flaws.








2. Measure the top of cylinder block (cylinder head mating face) for warpage. If warpage exceeds the specified limit, correct with a grinder.
Warpage of surface:
Less than 0.1 mm (0.004 in)
Surface grinding limit;
The grinding limit of cylinder block is determined by the cylinder head grinding in an engine.
Depth of cylinder head grinding is "A"
Depth of cylinder block grinding is "B"
The limit is as follows:
A + B = 0.2 mm (0.008 in)
Cylinder block height (nominal):
214 ± 0.05 mm (8.4252 ± 0.0020 in)








3. Using a bore gauge, measure cylinder bore for wear, out-of-round or taper. If they are excessive, rebore the cylinder walls with a boring machine. Measurement should be taken along bores for taper and around bores for out-of-round.
Out-of-round: X-Y
Taper: A-B

4. When wear, taper or out-of-round is minor and within the limit, remove the step at the topmost portion of cylinder using a ridge reamer or other similar tool.

When installing service cylinder liner, interference fit of cylinder liner in cylinder block should be 0.080 to 0.090 mm (0.0031 to 0.0035 in).

CYLINDER BORING
When any cylinder needs boring, all other cylinders must also be bored at the same time.

Determining bore size
1. Determine piston oversize according to amount of cylinder wear. Refer to Specifications.





2. The size to which cylinders must be honed is determined by adding piston-to-cylinder clearance to the piston skirt diameter.





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 : Honing allowance 0.02 mm (0.0008 in)

Boring
1. Install main bearing caps in place, and tighten to the specified torque to prevent distortion of the cylinder bores in final assembly.
2. Cut cylinder bores.

Caution: Do not out 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.
Bore the cylinders in the order of 2-4-1-3 to prevent heat strain due to cutting.

3. Hone the cylinders to the required size referring to Specifications.
^ Use clean sharp stones of. proper grade.
^ Cross-hatch pattern should be approximately 45°.

4. Measure the finished cylinder bore for out-of-round and taper.





Measuring piston-to-cylinder clearance
Measure the extracting force, and pull feeler gauge straight upward. It is recommended that piston and cylinder be heated to 20°C (68° F).

Feeler gauge thickness: 0.04 mm (0.0016 in)
Extracting force: 4.9-14.7 N (0.5 - 1.5kg, 1.1 - 3.3 lb)

PISTON, PISTON PIN AND PISTON RING

PISTON
1. Scrape carbon off piston and ring grooves with a carbon scraper and a curved steel wire. Clean out oil slots in bottom band of oil ring grooves.
2. Check for damage, scratches and wear. Replace if such a fault is detected.





3. Measure the side clearance of rings in ring grooves as each ring is installed.
Max. toler8nce of side dearance: 0.2 mm (0.008 in)
If side clearance exceeds the specified limit, replace piston together with piston ring.





PISTON RING
Measure ring gap with a feeler gauge, placing ring squarely in cylinder using piston. Ring should be placed to diameter at upper or lower limit of ring travel.
Max. tolerance of ring gap: 1.0 mm (0.039 in)

a. When only piston ring is to be replaced, without cylinder bore being corrected, measure the gap at the bottom of cylinder where the wear ii minor.
b. Oversize piston rings are available for service.





PISTON PIN
1. Check piston pin and piston pin hole for signs of sticking and other abnormalities.
2. Measure piston pin hole in relation to the outer diameter of pin. If wear exceeds the limit, replace such piston pin together with piston on which it is installed.
Piston pin to piston clearance: 0.008 - 0.012 mm (0.0003-0.0005 in)

Note: Determine the fitting of piston pin into piston pin hole to such an extent that it can be pressed smoothly by finger at room temperature.





CONNECTING ROD
1. If a connecting rod has any flaw on both sides of the thrust face and the large end, correct or replace it.
2. Check connecting rod for bend or torsion using a connecting rod aligner. If bend or torsion exceeds the limit, correct or replace.
Bend and torsion [per 100 mm (3.94 in) length): Less than 0.05 mm (0.0020 in)

3. Install connecting rods with bearings on to corresponding crank pins and measure the thrust clearance. If the measured value exceeds the limit, replace such connecting rod.
End play limit: 0.5 mm (0.020 in)





CRANKSHAFT

CRANK JOURNAL AND PIN
1. Repair or replace as required. If faults are minor, correct with fine crocus cloth.
2. Check journals and crank pins with a. micrometer for taper and out- of-round. Measurement should be taken along journals for taper and around journals for out-of-round.





If out-of-round or taper exceeds the specified limit, replace or repair.
Out-of-round (X-Y) and Taper (A-B): Less than 0.01 mm (0.0004 in)

3. After regrinding crankshaft, finish it to the necessary size indicated in the chart under Specification by using an adequate undersize bearing according to the extent of required repair.





RUNOUT AND END PLAY
1. Crankshaft can be checked for runout by placing it on V-blocks and using a dial gauge with its indicating finger resting on the center journal.
If bend exceeds the specified limit,replace or repair.
Runout [T.l.R.]: Limit 0.08 mm (0.0031 in)





2. Install crankshaft in cylinder block and measure crankshaft free end play at the center bearing.
End play limit: 0.30 mm (0.0118 in)

MAIN BEARING AND CONNECTING ROD BEARING

MAIN BEARING
1. Thoroughly clean all bearings and check for scratches, melt, score or wear. Replace bearings, if any fault is detected.





2. Measure bearing clearance as follows:
(1) Cut a plastigage to the width of bearing and place it in parallel with crank journal, getting clear of the oil hole.
(2) Install crankshaft, bearings and bearing cap, with the bolts tightened to the specified torque.
(T) : Main bearing cap 49-59 N.m (5.0 - 6.0 kg-m, 36-43 ft-lb)

Note: Do not turn crankshaft while the plastigage is being inserted.





(3) Remove cap, and compare width of the plastigage at its widest part with the scale printed in the plastigage envelope.
Max. tolerance of main bearing clearance: 0.10 mm (0.0039 in)

3. If clearance exceeds the specified value, replace bearing with an undersize bearing and grind crankshaft journal adequately. Refer to Specifications.

CONNECTING ROD BEARING
1. Measure connecting rod bearing clearance in the same manner as above.
(T) : Connecting rod bearing cap 31 - 37 N-m (32 - 3.8 k-m, 23-27 ft-lb)
Max. tolerance of connecting rod bearing clearance: 0.10 mm (0.0039 in)
2. If clearance exceeds the specified value, replace bearing with an undersize bearing and grind the crankshaft journal adequately. Refer to Specifications.

JACK SHAFT AND JACK SHAFT BUSHING





JACK SHAFT BEARING CLEARANCE
Journal diameters should be checked with a micrometer, and bearings with an inside dial gauge. Measurements should then be compared to determine whether bearings are worn.
Max. tolerance of jack shaft bearing clearance: 0.15 mm (0.0059 in)





Replacing back shaft bushing
1. Remove jack shaft bushings with suitable tool.
2. Install new bushings with suitable tool.
a. Align cylinder block oil hole and bushing oil hole.
b. Check bushing dearance.
c. Install welch plug into cylinder block, applying sealant.





FLYWHEEL
1. Check the clutch disc contact surface on flywheel for damage or wear. Repair or replace if necessary.
2. Measure runout of the clutch disc contact surface with a dial gauge. If it exceeds the specified limit, replace it.
Runout: (Total indicator reading) Less than 0.15 mm (0.0059 in)
3. Check tooth surfaces of ring gear for flaws or wear. Replace if necessary. Install ring gear on fly wheel, heating ring gear to about 180 to 220°C (356 to 428°F).





OIL SEAL
Check front, and rear oil seals for worn or folded over sealing lip and oil leakage. If necessary, replace with a new seal. When installing a new front or rear seal, pay attention to its mounting direction.

Note: It is good practice to renew oil seal whenever engine is overhauled.





PRECAUTIONS
1. When installing sliding parts such as bearings, be sure to apply engine oil on the sliding surfaces.
2. Use new packings and oil seals.
3. Be sure to follow the specified order and tightening torque.
4. Applying sealant
Use sealant to eliminate water and oil leaks. Do not apply too much sealant Part requiring sealant is: Mating surface of oil pan gasket and oil seals.





ASSEMBLY

PISTON AND CONNECTING ROD
1. Assemble pistons, piston pins and connecting rods of the designated cylinders.
a. Piston pin is pressed into connecting rod. and fitting force should be within the specified limit.
Piston pin fitting force: 4.9-14.7 kN (0.5-1.5t,0.6-1.7 US ton. 0.49-1.48 Imp ton)

When pressing piston pin in connecting rod, apply engine oil to pin and small end of connecting rod.





b. Arrange so that oil hole of connecting rod big end is directed toward the right side of cylinder block.
c. Connecting rods are marked at side of big end for identifying the designated cylinder.
d. Connecting rod with same weight tolerance is available only as a set of four.





2. Install piston rings.
Install so that stamped mark on ring faces upward.

ENGINE OVERALL INTERNAL PARTS
First, mount cylinder block on engine stand.





1. Crankshaft
(1) Set upper main bearings at the proper portion of cylinder block.

a. Only center bearing (No. 3) is a flange type.
b. Front bearing (No. 1) is also the same type as rear bearing (No.5).
c. Other inter bearings, except center bearing, are the same type.

(2) Apply engine oil to main bearing surfaces on both sides of cylinder block and cap.
(3) Install crankshaft.








(4) Install main bearing cap and tighten bolts to specified torque.
Main bearing cap bolts 49 - 59 Nm (5.0-6.0 k-m, 36-43 ft-lb)

a. Arrange the parts so that the figure on bearing cap faces toward the water pump.
b. Prior to tightening bearing cap bolts. place bearing cap in proper position by shifting crankshaft in the axial direction.
c. Tighten bearing cap bolts gradually in separating two to three stages and in sequence outwardly from center hearing.
d. After securing bearing cap bolts, ascertain that crankshaft turns smoothly by hand.





(5) Make sure that there exists proper end play at crankshaft.





(6) Install oil seal retainer.

a. When installing oil seal retainer, give coating of engine oil to mating shaft to prevent scratches and folded lip. Also apply coating of oil to periphery of oil seal.
b. Install oil seal in the direction that dust seal lip faces to the outside of crankcase.





2. Piston with connecting rod.
(1). Install them into corresponding cylinders.

a. Apply engine oil to sliding parts.
b. Arrange so that the front mark on piston head faces to the front of engine.





c. Set piston rings as shown below.





(2) Install connecting rod caps.
Connecting rod cap nuts 31 37 Nm (3.2 - 3.8 kg-m, 23 - 27 ft-lb).

Arrange connecting rods and connecting rod caps so that the cylinder numbers face in the same direction.

(3) Make sure that there exists proper end play at connecting rod big end. Refer to Inspection and Repair.





3. Rear plate and flywheel or drive plate
Tighten:
Flywheel fixing bolts 78 - 88 N-m (8.0 - 9.0 kg-m, 58-65ft-lb)
Drive plate fixing bolts 93 - 103 N-m (9.5 - 10.5 kg-m, 69 - 76 ft-lb).

Note: Do not lock at ring gear.





4. Install jack shaft.

Caution: Be careful not to damage the inner surface of lack shaft bushing.

5. Install jack shaft locating plate.
6. Install water pump assembly with new gasket.
7. Install oil pan.

Tighten: Oil pan fixing bolts 4-6 N-m (0.4 - 0.6 kg-m, 2.9- 4.3 ft-lb)





8. Install crank oil thrower, then install cylinder block cover together with oil seal collar.

Caution: Be careful not to damage the oil seal lip.

9. Install jack shaft pulley.

Tighten lack shaft pulley bolt by holding pulley with hand.
Tighten : Jack shaft pulley fixing bolt 9-12 N-m (0.9 - 1.2 kg-m, 6.5 - 8.7 ft-lb)





10. Install crankshaft timing pulley.





11. Temporarily install tensioner.
12. Install cylinder head assembly and gasket by accommodating knock pin of cylinder block as follows:
(1) Thoroughly clean cylinder block and head surface.

Note: Do not apply sealant to any other part of cylinder block and head surface.





(2) Turn crankshaft and set No. 1 cylinder at top dead center on its compression stroke: This causes crankshaft timing pulley mark to be aligned with cylinder block cover mark.








(3) Align camshaft pulley mark with cylinder head cover mark. This causes valves for No.1 cylinder to position at top dead center on compression stroke.
(4) Install cylinder gasket and cylinder head assembly.
(5) Tighten cylinder head bolts.

a. Do not rotate crankshaft and camshaft separately, because valves will hit piston heads.
b. Always use new cylinder head gasket.
c. There are three kinds of cylinder head bolts with different lengths.
d. Be sure to install washers between cylinder head and bolts.





Tightening order
Tightening procedures
(1) Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb).
(2) Tighten all bolts to 69 N-m (7.0 kg-m, 51 ft-lb).
(3) Loosen all bolts completely.
(4) Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb).
(5) Tighten all bolts to 69 to 74 N-m (7.0 to 7.5 kg-m, 51 to 54 ft-lb) or if you have an angle wrench, turn each bolt clockwise the specified number of degrees.





Specified number of degrees:
(A) 45
(B) 55
(C) 40

When performing normal maintenance and inspection, first loosen each cylinder head bolt slightly, then tighten' to a torque of 69 to 74 N-m (7.0 to 7.5 kg-m, 51 to 54 ft-lb). (This should be done when engine is cold).

(6) Install spark plugs.
Tighten : 20 - 29 N-m (2.0-3.0 kg-m, 14 - 22 ft-lb)

FRONT SIDE PARTS
1. Install water pump pulley.
2. Install spacer and upper and lower dust cover.
3. Install crankshaft pulley.
Tighten: Crankshaft pulley bolt 113 - 147 N-m (11.5 - 15.0 k-m, 83-108 ft-lb)

LEFT SIDE PARTS
1. Install exhaust manifold.
Tighten: Exhaust manifold fixing nut 16-21 N-m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
2. Install cooler compressor bracket and power steering bracket.

RIGHT SIDE PARTS
1. Install oil pump assembly with new gasket.
Tighten: Oil pump bolt & nuts 8-10 N-m (0.8 - 1.0 kg-m, 5.8-7.2 ft-lb)
2. Install fuel pump assembly with insulator.
Tighten: Fuel pump nuts 9.1 - 11.8 N-m (0.93- 1.2 kg-m, 6.7-8.7 ft-lb)

Note: Always replace gaskets.

3. Install oil filter.
4. Install alternator bracket and alternator.
Tighten: Alternator bracket fixing bolt 8-10 N-m (0.8 - 1.0 kg-m, 5.8 - 7.2 ft-lb)
Alternator to bracket bolt 44-59 N-m (4.5 - 6.0 kg-m, 33 - 43 ft-lb)

5. Install intake manifold with carburetor.
Tighten: Intake manifold fixing nuts 16-21 N-m (1.6-2.1 k-m, 12 - 15 ft-lb)

REAR SIDE PARTS
1. Install thermostat housing with distributor.
Tighten: Thermostat housing fixing bolt 4-6 Nm (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-lb)
2. Install clutch unit using Tool KV30101000.
Tighten: Clutch unit fixing bolt 22 - 29 N-m (2.2-3.0 kg-m, 16 - 22 ft-lb)