Cylinder Block Assembly: Service and Repair
Legend
1 RH rear engine mounting (M/T models)
2 Front engine slinger
3 RH front engine mounting
4 Center member
5 LH front engine mounting
6 LH rear engine mounting (M/T models)
7 LH rear engine mounting (A/T models)
8 Rear engine slinger
9 RH rear engine slinger (A/T models)
WARNING:
a. Position vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels. A
c. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line.
d. For safety during subsequent steps, the tension of wires should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to "Release Fuel Pressure".
f. Before removing front axle from transaxle, place safety stands under designated front supporting points.
g. Be sure to hoist engine and transaxle in a safe manner.
h. For engines not equipped with engine slingers, attach proper slingers and bolts.
CAUTION:
^ When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder.
^ In hoisting the engine, always use engine slingers in a safe manner.
^ In removing drive shaft, be careful not to damage grease seal of transaxle.
Removal
1. Remove engine under cover and hood.
2. Drain coolant from both cylinder block, and radiator.
3. Remove vacuum hoses, fuel hoses, wires, harnesses and connectors and so on.
4. Remove exhaust tubes, ball joints and drive shafts.
5. Remove radiator and fans.
6. Remove drive belts.
7. Remove alternator, compressor and power steering oil pump from engine.
8. Set a suitable transmission jack under transaxle. Hoist engine with engine slinger.
9. Remove LH rear engine mounting.
10. Remove RH rear engine mounting
11. Remove center member and then slowly lower transmission jack.
12. Remove engine with transaxle as shown.
INSTALLATION
1. Installation is in the reverse order of removal.
Legend
1 Oil level gauge guide
2 Rear oil seal retainer
3 Cylinder block
4 Front cover
5 Oil strainer
6 Upper main bearing
7 Lower main bearing
8 Drain plug
9 Oil pan
10 Main bearing beam
11 Crankshaft
12 Pilot bushing or pilot converter
13 Oil separator
14 Rear plate (M/T models)
15 Rear plate (A/T models)
16 Flywheel or driver plate
17 Drive plate reinforcement
18 Oil ring
19 Piston pin
20 Connecting rod bearing
21 Connecting rod
22 Piston
23 2nd ring
24 Top ring
CAUTION:
^ When installing sliding parts such as bearings and pistons, be sure to apply 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. Place engine on a work stand.
3. Drain coolant and oil.
4. Remove cylinder head. Refer to "Removal" in "TIMING CHAIN".
5. Remove oil pan. Refer to "Removal" in "OIL PAN".
6. Remove timing chain. Refer to "Removal" in "TIMING CHAIN".
7. 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.
8. Remove rear oil seal retainer.
9. Remove main bearing beam and crankshaft.
^ Before removing main bearing beam, 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)
If it exceeds the above value, replace piston assembly with pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.040 - 0.080 mm (0.0016 - 0.0031 in)
2nd ring
0.030 - 0.063 mm (0.0012 - 0.0025 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
End gap:
Top ring 0.21 - 0.40 mm (0.0083 - 0.0157 in)
2nd ring 0.50 - 0.69 mm (0.0197 - 0.0272 in)
Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
1.0 mm (0.039 in)
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. When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure is found, hone or replace the cylinder block.
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
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.
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.
Resurfacing limit:
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:
227.80 - 227.70 mm (8.9606 - 8.9645 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:
87.000 - 81.030 mm (3.4252 - 3.4264 in)
Wear limit:
0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
Out-of-round (X - Y) standard:
0.015 mm (0.0006 in)
Taper (A - B) standard:
0.010 mm (0.004 in)
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):
16.5 mm (0.650 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.015 - 0.035 mm (0.0006 - 0.0014 in)
5. Determine piston oversize according to amount of cylinder wear. 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 0.10 mm (0.0039 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 to cylinder block.
Tighten all bolts in correct order in two or three stages.
3. Measure inner diameters "A" of each main bearing.
4. Measure outer diameters "Dm" of each crankshaft main journal.
5. Calculate main bearing clearance.
Main bearing clearance = A - Dm
Standard: 0.028 - 0.055 mm (0.0011 - 0.0022 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.
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. These numbers are punched in either Arabic or Roman numerals.
b. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the following calculation or image.
Example of calculation:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number = 1 + 2 = 3 (Yellow)
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: 0.028 - 0.048 mm (0.0011 - 0.0019 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 image.
a. Grade number of each connecting rod big end is punched on the respective connecting rod. These numbers are punched in either Arabic or Roman numerals.
b. Grade number of each crankshaft pin journal is punched on the No.5 counter weight of crankshaft. These numbers are punched in either Arabic or Roman numerals.
c. Select connecting rod bearing with suitable thickness according to the following calculation and image.
Example of calculation:
Connecting rod big end grade number: 1
Crankshaft pin grade number: 2
Connecting rod bearing grade number
=1+2
= 3 (Yellow)
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" of piston pin.
3. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C - Dp
Standard: 0.005 - 0.017 mm (0.0002 - 0.0001 in)
Limit: 0.023 mm(0.0009 in)
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 0.15 mm (0.0059 in)
Drive plate (A/T model)
Less than 0.15 mm (0.0059 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 beam.
^ Confirm that correct main bearings are used. Refer to "Inspection" of this section.
2. Install crankshaft and main bearing beam and tighten bolts to the specified torque.
^ Prior to tightening bearing beam bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction.
^ Tighten bearing beam bolts gradually in two or three stages. Start with center bearing and move outward sequentially.
^ After securing bearing beam bolts, make sure crankshaft turns smoothly by hand.
3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.05 - 0.11 mm (0.0020 - 0.0067 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace bearing with a new one.
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 connecting 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 with the connecting rod.
^ Arrange so that front mark on piston head faces toward front of engine.
b. Install connecting rod caps. Tighten connecting rod bearing cap nuts to the specified torque.
Connecting rod bearing nut:
(1) Tighten to 14 to 16 Nm (1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2) Turn nuts 60 to 65 degrees clockwise.
If an angle wrench is not available, tighten nuts to 59 to 65 Nm (6.0 to 6.6 kg-m, 43 to 48 ft-lb).
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20-0.35 mm (0.0079 - 0.0138 in)
Limit
0.40 mm (0.0151 in)
If beyond the limit, replace connecting rod and/or crankshaft.
7. Install rear oil seal retainer.