Cylinder Block Assembly: Service and Repair
Legend
(1) Rear oil seal retainer
(2) Cylinder block
(3 Water pump
(4) Power steering oil pump adjusting bar
(5) Front cover with oil pump
(6) Oil strainer
(7) Thrust bearing
(8) Crankshaft
(9) Connecting rod bushing
(10) Piston rings
(11) Piston
(12) Piston pin
(13) Connecting rod
(14) Connecting rod bearing
(15) Baffle plate
(16) Aluminum oil pan
(17) Rear cover plate
(18) Drain plug
(19) Steel oil pan
(20) Baffle plate
(21) Side gallery baffle plate
(22) Main bearing beam
(23) Main bearing cap
(24) Flywheel or drive plate
(25) Rear plate
(26) Main bearing
CAUTION:
^ When installing sliding parts such as bearings and pistons, be sure to apply new engine oil on the sliding surfaces.
^ Place removed parts such as bearings and bearing caps in their proper order and direction.
^ When tightening connecting rod bolts and main bearing cap bolts, apply engine oil to thread portion of bolts and seating surface of nuts.
DISASSEMBLY
PISTON AND CRANKSHAFT
1. Remove engine. Refer to "ENGINE REMOVAL".
2. Remove cylinder head. Refer to "Removal" in "TIMING CHAIN".
3. Remove oil pan. Refer to "Removal" in "OIL PAN".
4. Remove timing chain. Refer to "Removal" in "TIMING CHAIN".
5. Remove pistons with connecting rod.
^ When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature.
6. Remove rear oil seal retainer.
7. Remove bearing beam, bearing cap and crankshaft.
^ Before removing bearing cap, measure crankshaft end play.
^ Bolts should be loosened in two or three steps.
INSPECTION
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp":
21.987 - 21.999 mm (0.8656 - 0.8661 in)
2. Measure outer diameter of piston pin "Dp".
Standard diameter "Dp":
21.989- 22.001 mm (0.8657 - 0.8662 in)
3. Calculate piston pin clearance.
dp - Dp = -0.004 to 0 mm (-0.0002 to 0 in)
Note: If it exceeds the above value, replace piston assembly with pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.045- 0.080 mm (0.0018 - 0.0031 in)
2nd ring
0.030- 0.065 mm (0.0012 - 0.0026 in)
Max. limit of side clearance:
0.2 mm (0.008 in)
Note: If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
End gap:
Top ring
0.20-0.30 mm (0.0079 - 0.0118 in)
2nd ring
0.35-0.50 mm (0.0138 - 0.0197 in)
Oil ring
0.20-0.60 mm (0.0079 - 0.0236 in)
Max. limit of ring gap:
1.0 mm (0.039 in)
Note: If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to Specifications.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
Note: If it exceeds the limit, replace connecting rod assembly.
CYLINDER BLOCK DISTORTION AND WEAR
1. Clean upper face of cylinder block and measure the distortion.
Standard:
Less than 0.03 mm (0.0012 in)
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it.
^ The resurfacing limit is determined by cylinder head resurfacing in 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:
211.25-211.35 mm (8.3169 - 8.3208 in)
3. If necessary, replace cylinder block.
PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper.
Standard inner diameter:
86.000- 86.030 mm (3.3858 - 3.3870 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round limit:
0.015 mm (0.0006 in)
Taper limit:
0.010 mm (0.0004 in)
Note: If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
2. Check for scratches and seizure. If seizure is found, hone it.
^ If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block upper surface.
3. Measure piston skirt diameter.
Piston diameter "A":
Refer to Specifications.
Measuring point "a" (Distance from the bottom):
11.0 mm (0.433 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.010 - 0.030 mm (0.0004 - 0.0012 in)
5. Determine piston oversize according to amount of cylinder wear.
Note: Oversize pistons are available for service.
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A".
Rebored size calculation:
D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque to prevent distortion of cylinder bores in final assembly.
8. Cut cylinder bores.
^ When any cylinder needs boring, all other cylinders must also be bored.
^ Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
^ Measurement should be done after cylinder bore cools down.
CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or cracks.
2. With a micrometer, measure journals for taper and out-of-round.
Out-of-round (X - Y):
Less than 0.005 mm (0.0002 in)
Taper (A - B):
Less than 0.005 mm (0.0002 in)
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.05 mm (0.0020 in)
BEARING CLEARANCE
Either of the following two methods may be used, however, method "A" gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing
1. Set main bearings in their proper positions on cylinder block and main bearing cap.
2. Install main bearing cap and main bearing beam to cylinder block.
Tighten all bolts in correct order in two or three stages.
3. Measure inner diameter "A" of each main bearing.
4. Measure outer diameter "Dm" of each crankshaft main journal.
5. Calculate main bearing clearance.
Main bearing clearance A - Dm
Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in)
Limit: 0.050 mm (0.0020 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.
a. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 in)
b. Refer to Specifications for grinding crankshaft.
8. If crankshaft is reused, measure main bearing clearances and select thickness of main bearings.
^ If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows:
a. Grade number of each cylinder block main journal is punched on the respective cylinder block.
b. Grade number of each crankshaft main journal is punched on the respective crankshaft.
c. Select main bearing with suitable thickness according to the following table.
Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard:
0.020 - 0.045 mm (0.0008 - 0.0018 in)
Limit:
0.090 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.
Refer to step 7 of "BEARING CLEARANCE - Main bearing".
8. If crankshaft is replaced with a new one, select connecting rod bearing according to the images.
Method B (Using plastigage)
CAUTION:
^ Do not turn crankshaft or connecting rod while plastigage is being inserted.
^ When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.
CONNECTING ROD BUSHING CLEARANCE (Small end)
1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp 0 piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C Dp
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit:
0.023 mm (0.0009 in)
Note:If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.
REPLACEMENT OF CONNECTING ROD BUSHING (Small end)
1. Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing so that clearance between connecting rod bushing and piston pin is the specified value.
Clearance between connecting rod bushing and piston pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Flywheel (M/T model)
Less than 0.10 mm (0.0039 in)
Drive plate (A/T model)
Less than 0.20 mm (0.0079 in)
ASSEMBLY
PISTON
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70±C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring.
^ Align the direction of piston and connecting rod.
^ Numbers stamped on connecting rod and cap correspond to each cylinder.
^ After assembly, make sure connecting rod swings smoothly.
3. Set piston rings as shown.
CAUTION:
^ When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
^ When piston rings are being replaced and no punchmark is present, piston rings can be mounted with either side up.
CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block and main bearing cap.
^ Confirm that correct main bearings are used.
2. Install crankshaft, main bearing caps and beam and tighten bolts to the specified torque.
Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction.
Tightening procedure
1) Tighten bolts to 32 to 38 N-m (3.3 to 3.9 kg-m, 24 to 28 ft-lb).
2) Turn bolts 45 to 50 degrees clockwise or if angle wrench is not available, tighten bolts to 73 to 82 N-m (7.4 to 8.4 kg-m, 54 to 61 ft-lb).
^ After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.10-0.26 mm (0.0039 - 0.0102 in)
Limit
0.30 mm (0.0118 in)
Note: If beyond the limit, replace thrust bearings with new ones.
4. Install connecting rod bearings in connecting rods and connecting rod caps.
^ Confirm that correct bearings are used. Refer to "Inspection".
^ Install bearings so that oil hole in connectin9 rod aligns with oil hole of bearing.
5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
^ Be careful not to scratch cylinder wall by connecting rod.
^ Arrange so that front mark on piston head faces toward front of engine.
b. Install connecting rod caps.
Tighten connecting rod cap nuts to the specified torque.
Tightening procedure:
1) Tighten nuts to 14 to 16 N-m (1.4 to 1.6 kg-m, 10 to 12 if-lb).
2) Turn nuts 60 to 65 degrees clockwise or if angle wrench is not available, tighten nuts to 38 to 44 N-m (3.9 to 4.5 kg-m, 28 to 33 ft-lb).
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20-0.35 mm (0.0079 - 0.0138 in)
Limit
0.50 mm (0.0197 in)
Note: If beyond the limit, replace connecting rod and/or crankshaft.
7. Install rear oil seal retainer.
(1) Before installing rear oil seal retainer, remove all traces of liquid gasket from mating surface using a scraper.
^ Also remove traces of liquid gasket from mating surface of cylinder block.
(2) Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer.
^ Use Genuine Liquid Gasket or equivalent.