Cylinder Block Assembly: Service and Repair
COMPONENT
REMOVAL
NOTE: Before conducting this procedure, drain the engine oil completely.
1. Remove the crank pulley.
2. Remove the front chain cover.
3. Remove the timing chain assembly.
4. Remove the cam sprocket.
5. Remove the crank sprocket.
6. Remove the rear chain cover.
7. Remove the camshaft.
8. Remove the cylinder head.
9. Remove the drive plate. Lock the crankshaft using ST.
ST 498497100 CRANKSHAFT STOPPER
10. Remove the crankshaft position sensor plate.
11. Remove the crankshaft position sensor bracket.
12. Rotate the engine to set oil pan upper.
13. Remove the bolts which secure oil pan lower to oil pan upper.
14. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.
CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
15. Remove the oil strainer.
16. Remove the bolts which install oil pan upper onto cylinder block.
NOTE: Installation bolts have five different sizes. To prevent the confusion in installation, keep these bolts on container individually.
17. Remove the service hole cover and service hole plugs using a hexagon wrench.
18. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders using ST.
ST 18233AA000 PISTON PIN SNAP RING PRIERS
19. Draw out the piston pin from #1 and #2 pistons using ST.
ST 499097500 PISTON PIN REMOVER
NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
20. Similarly remove the piston pins from #3, #4, #5 and #6 pistons.
21. Remove the bolts which secure the cylinder block.
22. Separate the cylinder block (LH) and (RH).
NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
23. Remove the rear oil seal.
24. Remove the crankshaft together with connecting rod.
25. Remove the crankshaft bearings from cylinder block using a hammer handle.
NOTE:
^ Do not confuse the combination of crankshaft bearings.
^ Press the bearing at the end opposite to locking lip.
26. Draw out each piston from cylinder block using a wooden bar or hammer handle.
NOTE: Be careful not to confuse the original combination of piston and cylinder.
INSTALLATION
1. After setting the cylinder block to ST, install the crankshaft bearing.
ST 18232AA000 ENGINE STAND
NOTE: Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.
2. Position the crankshaft and connecting rod on the #2, #4 and #6 cylinder block.
3. Apply liquid gasket to the mating surface of #1, #3 and #5 cylinder block, and position it on #2, #4 and #6 cylinder block.
Liquid gasket: THREE BOND 1215B (Part No. 004403007)
NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
4. Apply a coat of engine oil to washers and bolt threads.
5. Tighten all bolts in the numerical order as shown in the figure.
6. Retighten all bolts in the numerical order as shown in the figure.
7. Tighten all bolts 90° in the numerical order as shown in the figure.
8. Install the upper bolt to cylinder block.
Tightening torque: 25 Nm (2.5 kgf-m, 18 ft. lbs.)
NOTE: Remove the liquid gasket which is running over to sealing surface between cylinder block and rear chain cover, cylinder block and oil pan upper, after tightening the bolts which combine the cylinder block.
9. Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
NOTE: Apply engine oil to the pressing-in portion.
10. Position the top ring gap at (A) in the figure.
11. Position the second ring gap at (B).
12. Position the upper rail gap at (C) in the figure.
13. Position the expander gap at (D) in the figure.
14. Position the lower rail gap at (E) in the figure.
CAUTION:
^ Ensure ring gaps do not face the same direction.
^ Ensure ring gaps are not within the piston skirt area.
^ Ensure R mark faces to top side of piston.
15. Install the snap ring. Install snap rings in the piston holes located opposite to the service holes in cylinder block, when positioning all pistons in the corresponding cylinders.
NOTE: Use new snap rings.
16. Installing the piston:
1 Using ST1, turn the crankshaft so that #3 and #4 connecting rods small end are set on the service hole (A).
ST1 18252AA000 CRANKSHAFT SOCKET
2 Apply a thin coat of engine oil to piston and cylinder.
3 Using ST2, press-fit the piston into cylinder.
ST2 18254AA000 PISTON GUIDE
NOTE: Piston front mark (A) faces towards the front of engine.
17. Installing piston pin:
1 Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to align piston pin hole with connecting rod small end.
ST3 18253AA000 PISTON GUIDE
2 Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
3 Using the ST4, install the snap ring.
ST4 18233AA000 PISTON PIN SNAP RING PRIERS
NOTE: Use new snap rings.
4 Similarly install the #1, #2, #5 and #6 pistons.
18. Install the service hole plug and O-ring.
NOTE: Use a new O-ring.
19. Apply liquid gasket to the matching surface of oil pan upper.
NOTE: Use new O-rings.
20. Temporarily tighten the oil pan upper.
NOTE: Do not install the bolts in wrong place.
21. Tighten the oil pan upper installing bolts in the numerical order as shown in the figure.
22. Install the oil strainer.
23. Apply liquid gasket to the matching surface of oil pan lower.
Liquid gasket: THREE BOND 1280B (Part No. K0877YA018)
24. Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.
25. Install the crankshaft sensor bracket.
26. Install the crankshaft sensor plate.
27. Install the drive plate. To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
28. Install the cylinder head.
29. Install the camshaft.
30. Install the rear chain cover.
31. Install the crank sprocket.
32. Install the cam sprocket.
33. Install the timing chain assembly.
34. Install the front chain cover.
35. Install the crank pulley.
DISASSEMBLY
1. Remove the connecting rod cap.
2. Remove the connecting rod bearing.
NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion.
3. Remove the piston rings using the piston ring expander.
4. Remove the oil ring by hand.
NOTE: Arrange the removed piston rings in proper order, to prevent confusion.
5. Remove the snap ring.
ASSEMBLY
1. Apply oil to the surfaces of the connecting rod bearings. Install the connecting rod bearings on connecting rods and connecting rod caps.
2. Install the connecting rod on crankshaft.
NOTE: Position each connecting rod with the side marked facing forward.
3. Install the connecting rod cap. Ensure the arrow on connecting rod cap faces the front during installation.
CAUTION:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number.
^ When tightening the connecting rod bolts, apply oil on the threads and flange end.
4. Install the oil ring spacer, upper rail and lower rail in this order by hand. Then install the second ring and top ring using a piston ring expander.
INSPECTION
CYLINDER BLOCK
1. Visually check for cracks and damage. Especially, inspect the important parts using liquid penetrant tester.
2. Check the oil passages for clogging.
3. Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge.
Standard height of cylinder block: 202 mm (7.95 inch)
CYLINDER AND PISTON
1. The cylinder bore size is stamped on the cylinder block's front upper surface.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston.
2. How to measure the inner diameter of each cylinder: Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge.
NOTE: Measurement should be performed at a temperature of 20°C (68°F).
Cylindricality:
Standard 0.030 mm (0.0012 inch)
3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. How to measure the outer diameter of each piston: Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction)
NOTE: Measurement should be performed at a temperature of 20°C (68°F).
Piston grade point H: 37.3 mm (1.4685 inch)
5. Calculate the clearance between cylinder and piston.
NOTE: Measurement should be performed at a temperature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard 0.010 - 0.010 mm (-0.00039 - 0.00039 inch)
6. Boring and honing:
1 If the value of cylindricality, out-of-roundness, or cylinder-to-piston clearance measured is out of standard or if there is any damage on the cylinder wall, rebore it to use an oversize piston.
CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only. Nor use an oversize piston for one cylinder only.
2 If the cylinder inner diameter exceeds 89.715 mm (3.5321 inch) after boring and honing, replace the crankcase.
NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter.
PISTON AND PISTON PIN
1. Check the pistons and piston pins for damage, cracks and wear, and the piston ring grooves for wear and damage. Replace if defective.
2. Measure the piston-to-cylinder clearance at each cylinder. If any of the clearances is not within specification, replace the piston or bore the cylinder to use an oversize piston.
3. Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective.
4. Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
5. Check the piston pin snap ring for distortion, cracks and wear.
PISTON RING
1. If the piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of the same size as the piston.
CAUTION:
^ Mark is displayed on the end of top and second rings. When installing the rings to the piston, face this mark upward.
^ Oil ring consists of the upper rail, expander and lower rail. When installing on piston, be careful of each rail's direction.
2. Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
3. Measure the clearance between piston ring and piston ring groove with a thickness gauge.
NOTE: Before measuring the clearance, clean the piston ring groove and piston ring.
CONNECTING ROD
1. Replace the connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist.
3. Install the connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). If side clearance exceeds the limit or offset wearing is emitted, replace the connecting rod.
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within the specification, replace the defective bearing with a new one of standard size or undersize as necessary.
6. Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end.
7. Replacement procedure is as follows.
1 Remove the bushing from connecting rod with ST and press.
2 Press the bushing with ST after applying oil on the periphery of bushing.
ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER
3 Make two 3 mm (0.12 inch) holes in bushing. Ream the inside of bushing.
4 After completion of reaming, clean the bushing to remove chips.
CRANKSHAFT AND CRANKSHAFT BEARING
1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. Replace if defective.
2. Check the crankshaft for bend, and repair or replace if needed.
NOTE: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then check the crankshaft for bend using a dial gauge.
3. Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used.
4. Measure the thrust clearance of crankshaft at center bearing. If clearance exceeds the limit, replace the bearing.
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
6. Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary.