Cylinder Block Assembly: Service and Repair
DISASSEMBLY
PISTON AND CRANKSHAFT
1. Place engine on work stand with Tool.
2. Remove timing belt.
3. Drain coolant and oil.
4. Remove water pump.
5. Remove oil pan and oil strainer. Refer to "OIL PAN". Service and Repair
6. Remove cylinder head.
7. Remove pistons.
8. Remove bearing caps and crankshaft.
Place the bearings and caps in their proper order.
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:
0.008 - 0.012 mm (0.0003 - 0.0005 in)
Apply engine oil to piston pin.
PISTON RING SIDE CLEARANCE
Side clearance mm (in):
Top ring
0.040 - 0.073 (0.0016 - 0.0029)
2nd ring
0.030 - 0.063 (0.0012 - 0.0025)
Max. limit of side clearance (Top and 2nd rings):
0-2 (0.008)
Oil ring side clearance:
0.006 - 0.179 (0.0002 - 0.0070)
PISTON RING GAP
Standard ring gap mm (in):
Top ring
0.20-0.30 (0.0079 - 0.0118)
2nd ring
0.15-0.25 (0.0059 - 0.0098)
Oil ring
0.20-0.60 (0.0079 - 0.0236)
Max. limit of ring gap
1.0(0.039)
BEARING CLEARANCE
Main bearing clearance mm (in):
No.1, No.3 and No.5 bearings 0.031 - 0.056 (0.0012 - 0.0022)
No.2 and No.4 bearings 0.031 - 0.092 (0.0012 - 0.0036)
Limit 0.10 (0.0039)
Connecting rod bearing clearance mm (in):
0.010-0.044 (0.0004 - 0.0017)
Limit 0.10 (0.0039)
Main bearing
1. Install main bearings to cylinder block and main bearing caps.
2. Install main bearing caps to cylinder block.
Tighten all bolts in correct order and in two or three stages. 49-59N.m (5.0-6.0 kg-m, 36-43 ft-lb).
3. Measure inside diameter "A" of main bearing.
4. Measure outside diameter "Dm" of main journal in crankshaft.
5. Calculate main bearing clearance.
Main bearing clearance = A - Dm
Connecting rod bearing
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: 31-37 N.m (3.2 - 3.8 kg-m, 23 - 27 ft-lb)
3. Measure inside diameter "C" of bearing.
4. Measure outside diameter "Dp" of pin journal in crankshaft.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
CONNECTING ROD BEND AND TORSION
Bend and torsion:
Limit 0.05 mm (0.0020 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-Y):
Less than 0.01 mm (0.0004 in)
Taper (A-B):
Less than 0.01 mm (0.0004 in)
Limit: 0.03 mm (0.0012 in)
When regrinding crank pin and crank journal, fillets should be finished as shown.
R : 2.3 - 2.7 mm (0.091 - 0.106 in)
3. Check crankshaft runout.
Runout [T.l.R. (Total Indicator Reading)]
Less than 0.04 mm (0.0016 in)
Limit 0.08 mm (0.0031 in)
CYLINDER BLOCK DISTORTION AND WEAR
1. If beyond the specified limit, resurface it.
Resurfacing limit:
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)
Nominal cylinder block height from crankshaft center "A":
214.20 ± 0.05 mm (8.4331 ± 0.0020 in)
2. Using a bore gauge, measure cylinder bore for wear, out-of-round or taper.
Standard inner diameter mm (in):
76.00 - 76.05 (2.9921 - 2.9941)
Out-of-round (X-Y):
Limit 0.015 mm (0.0006 in)
Taper (A-B):
Limit 0.02 mm (0.0008 in)
3. Check for scratches or seizure. If seizure is found, hone it.
CYLINDER BORING
When any cylinder needs boring, all other cylinders must also be bored.
1. Determine piston size according to amount of cylinder wear. Oversize pistons are available for service. 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 "A".
Dimension -
About 12.3 mm (0.484 in)
Rebored size calculation
D = A + B - C = A + [0.003 to 0.023 mm (0.0001 to 0.0009 in)]
where,
D: Bored diameter
A: Skirt diameter as measured
B: Piston-to-wall clearance
C: Honing 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.
^ 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 referring to Specifications.
6. Measure the finished cylinder bore for out-of-round and taper.
^ 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.
^ Bore the cylinders in the order of 2-4-1-3 to prevent heat strain due to cutting.
PISTON TO CYLINDER WALL CLEARANCE
Using micrometer
1. Measure piston skirt diameter "A" and cylinder bore diameter.
Piston diameter "A":
Refer to Specifications. Measuring point "a":
12.3 mm (0.484 in)
2. Check that piston clearance is within the specification.
Piston clearance:
0.023 - 0.043 mm (0.0009 - 0.0017 in)
FLYWHEEL RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
ASSEMBLY
PISTON
a. Numbers are stamped on the connecting rod and cap corresponding to each cylinder. Care should be taken to avoid a wrong combination including bearing.
b. Arrange so that the front mark on piston head faces to the front of engine.
c. When pressing piston pin in connecting rod, apply engine oil to pin and small end of connecting rod.
d. After assembling, ascertain that piston swings smoothly.
e. Set piston rings as shown.
^ Install so that stamped mark on ring faces upward.
^ In the combined oil ring, upper rail is the same as lower one.
^ Apply engine oil to sliding parts.
CRANKSHAFT
1. Set main bearings in the proper position on cylinder block. If either crankshaft, cylinder block or main bearing is reused again,. it is necessary to measure main bearing clearance.
a. Only center bearing (No.3) is a flanged type.
b. All inter-bearings (No.2 and No.4) are the same type.
c. Front bearing (No. 1) is also the same type as rear bearing (No.5).
d. Upper and lower bearings are not interchangeable. Upper ones 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 the specified torque.
Tighten 49-59 N.m (5 - 6 kg-m, 36 - 43 ft-lb)
Tighten in two or three stages.
^ After securing bearing cap bolts, ascertain that crankshaft turns smoothly by hand.
4. Make sure that there exists proper end play of crankshaft at center bearing.
Crankshaft free end play:
Standard
0.05 - 0.165 mm (0.0020 - 0.0065 in)
Limit
0.30 mm (0.0118 in)
5. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
Caution:
^ Be careful not to scratch cylinder wall with connecting rod.
^ 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: Connecting rod bearing nut
31 - 37 N.m (3.2 - 3.8 kg-m, 23 - 27 ft-lb)
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.1 -0.37 mm (0.0039 - 0.0146 in)
Limit
0.50 mm (0.0197 in)
If beyond the limit, replace connecting rod and/or crankshaft.
7. Install oil pan. Refer to "OIL PAN ". Service and Repair