Cylinder Block
Cylinder Block
REMOVAL
NOTE:
Before conducting this procedure, drain the engine oil completely.
1) Remove the engine from vehicle.
2) Remove the crank pulley.
3) Remove the chain cover.
4) Remove the timing chain assembly.
5) Remove the cam sprocket.
6) Remove the crank sprocket.
7) Remove the camshaft.
8) Remove the cylinder head.
9) Using the ST, lock the crankshaft and remove drive plate.
ST 498497100 CRANKSHAFT STOPPER
10) Remove the crankshaft position sensor.
11) Remove the crankshaft position sensor plate.
12) Rotate the engine to set oil pan upper.
13) Remove the bolts which secure oil pan lower to oil pan upper.
14) Insert an oil pan cutter blade into the gap between oil pan upper and oil pan lower, and remove the oil pan lower.
CAUTION:
Do not use a screwdriver or similar tools in place of oil pan cutter.
15) Remove the oil cooler connector and remove oil cooler.
16) Remove the oil pump.
17) Remove the thermostat cover, and then remove the thermostat.
18) Remove the oil pan upper.
19) Set the engine with front side facing upward.
20) Remove the O-rings (10 pcs) under the cylinder block.
21) Mark the all connecting rod caps with the front direction and the number of cylinder from which they were removed.
22) Remove the 1, 4 connecting rod caps and pistons from cylinder block.
NOTE:
- Use the 3/8 inch (9.5 sq.) for extension and TORX(R) socket (E12).
- Remove the connecting rod cap by turning the crankshaft (ST) in counterclockwise direction after removing two connecting rod joint bolts.
- Mark the all connecting rod caps and pistons with the number of the cylinder from which they were removed.
- Removal of the connecting rod caps and pistons should be performed in three stages. First, remove the 1, 4 connecting rod caps and pistons at the same time, then remove the 2, 5 connecting rod caps and pistons at the same time, then 3, 6 connecting rod caps and pistons at the same time.
(1) Turn the crankshaft using ST, to set the 1 piston at the middle position between top dead center and bottom dead center.
ST 18252AA000 CRANKSHAFT SOCKET
(2) Remove the two# 1 connecting rod cap joint bolts, then remove the connecting rod cap.
(3) Remove the two 4 connecting rod cap joint bolts, then remove the connecting rod cap.
(4) Turn the crankshaft using ST, to set apart the crank pin and the 1 connecting rod large end position.
ST 18252AA000 CRANKSHAFT SOCKET
(5) Push the 1 connecting rod to the arrow direction, then remove the 1 piston and connecting rod from cylinder block.
(6) Turn the crankshaft using ST, to set apart the crank pin and the 4 connecting rod large end position.
ST 18252AA000 CRANKSHAFT SOCKET
(7) Push the 4 connecting rod to the arrow direction, then remove the 4 piston and connecting rod from cylinder block.
23) Remove the 2, 5 connecting rods and pistons from cylinder block in the same way.
ST 18252AA000 CRANKSHAFT SOCKET
24) Remove the 3, 6 connecting rods and pistons from cylinder block in the same way. ST 18252AA000 CRANKSHAFT SOCKET
25) Set the engine with the cylinder block (RH) facing upward.
26) Remove the upper bolt.
27) Loosen the cylinder block bolts in the numerical order as shown in the figure, then separate the cylinder block (RH) and (LH),
NOTE:
Make sure that the crankshaft remains in the cylinder block (LH).
Separating the cylinder block (RH) carelessly by lifting it will cause the crankshaft inside the cylinder block (RH) to fall down.
28) Remove the rear oil seal.
29) Remove the crankshaft from cylinder block (LH).
30) 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.
INSTALLATION
1) After setting the cylinder block to ST, install the crankshaft bearing.
ST 18232AA000 ENGINE STAND
NOTE:
Apply a coat of engine oil to the bearing and crankshaft journal.
2) Install the crankshaft to cylinder block (LH),
3) Apply liquid gasket to the matching surface of cylinder block (RH).
CAUTION:
Do not allow liquid gasket to run over to oil passages, bearing grooves, etc.
NOTE:
Install the oil pan lower within 5 minutes after applying liquid gasket.
Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Applying liquid gasket diameter. 1.0±0.2 mm (0.039±0.008 in)
4) Install the cylinder block (RH) to cylinder block (LH),
5) Apply a coat of engine oil to the washer and bolt thread.
6) Tighten all bolts in the numerical order as shown in the figure.
Tightening torque: 12 N-m (1.2 kgf-m, 8.9 ft-lb)
7) Retighten all bolts in the numerical order as shown in the figure.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)
8) Tighten all bolts 90 degrees in the numerical order as shown in the figure.
9) Install the upper bolt to cylinder block.
Tightening torque: 25 N-m (2.5 kgf-m, 18.4 ft-lb)
NOTE:
After tightening the cylinder block connecting bolts, remove the liquid gasket which is running over to the sealing surface for chain cover and oil pan upper.
10) Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2.
NOTE:
Use a new rear oil seal.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
11) Set the engine with front side facing upward.
12) Install the piston ring and oil ring to the piston.
(1) Position the top ring gap at (A) in the figure.
(2) Position the second ring gap at (B).
(3) Position the upper rail gap at (C) in the figure re.
(4) Position the expander gap at (D) in the figure re.
(5) Position the lower rail gap at (E) in the figure re.
CAUTION:
- Make sure ring gaps do not face the same direction.
- Make sure ring gaps are not within the piston skirt area.
- Assemble it so that R mark faces to top side of piston.
13) Install the 1 piston and connecting rod on the cylinder block.
(1) Apply engine oil to the periphery of piston and cylinder block inner surface.
(2) Set the piston in the ST with the front mark (A) facing the front of engine.
(3) Using the ST, press-fit the piston into cylinder block.
NOTE:
Follow the notes below while inserting the piton into the cylinder block.
- Insert the piston while tapping the top of piston using a plastic hammer handle.
- Continually check during insertion that the large end of the connecting rod will not scratch the cylinder liner.
- Insert the piston so that the connecting rod large end does not touch the crankshaft.
ST 398744300 PISTON GUIDE
(4) Turn the crankshaft using ST, to align the crank pin and the connecting rod large end position.
ST 18252AA000 CRANKSHAFT SOCKET
(5) Install the connecting rod cap.
Tightening torque: 60 N-m (6.1 kgf-m, 44.3 ft-lb)
14) In the same way as #1 piston, install the pistons and connecting rods to the cylinder block in the order of #2, #3, #4, #5, #6.
15) Install the O-ring under the cylinder block.
NOTE:
Use new O-rings.
16) Apply liquid gasket to the mating surface of oil pan upper.
NOTE: Install the oil pan lower within 5 minutes after applying liquid gasket.
Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Applying liquid gasket diameter: 5.0± 1.0 mm (0.20±0.04 in)
17) Temporarily tighten the oil pan upper.
18) Tighten the oil pan upper installing bolts in the numerical order as shown in the figure.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)
19) Install the oil pump.
20) Install the thermostat and thermostat cover.
Tightening torque: 6.4 N-m (0.7 kgf-m, 4.7 ft-lb)
21) Tighten the oil cooler connector and install the oil cooler to oil pan upper.
Tightening torque: 54 N-m (5.5 kgf-m, 39.8 ft-lb)
NOTE:
Use new O-rings.
22) Apply liquid gasket to the matching surface of oil pan lower.
NOTE:
Install the oil pan lower within 5 minutes after applying liquid gasket.
Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Applying liquid gasket diameter: 5.0±1.0 mm (0.20±0.04 in)
23) Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.
Tightening torque: 6.4 N-m (0.7 kgf-m, 4.7 ft-lb)
24) Install the crankshaft position sensor plate.
25) Install the crankshaft position sensor.
Tightening torque: 6.4 N-m (0.7 kgf-m, 4.7 ft-lb)
26) Using the ST, lock the crankshaft and install drive plate.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque: 90 N-m (9.2 kgf-m, 66.4 ft-lb)
27) Install the cylinder head.
28) Install the camshaft.
29) Install the crank sprocket.
30) Install the cam sprocket.
31) Install the timing chain assembly.
32) Install the chain cover.
33) Install the crank pulley.
34) Install the engine to the vehicle.
DISASSEMBLY
NOTE:
Mark each part to prevent parts mixing.
1) Remove the connecting rod bearing.
2) Remove the piston rings using piston ring expander.
3) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order, to prevent confusion.
4) Remove the snap ring.
5) Using a snap ring pliers, remove the snap ring.
6) Remove the piston pin from piston.
7) Separate the piston and connecting rod.
8) Remove the plug and orifice from cylinder block.
ASSEMBLY
1) Apply oil to the surfaces of the connecting rod bearings. Install the connecting rod bearings on connecting rods.
2) Joint the piston and connecting rod.
NOTE:
Position each connecting rod with the marking side facing forward.
3) Apply engine oil to the piston pin, then install the piston pin.
4) Using a snap ring pliers, install the snap ring.
5) Install the oil ring spacer, upper rail and lower rail by hand. Install the second ring and top ring using 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 cylinder block surface that mates with cylinder head for warping by using a straight edge. If the warpage exceeds limit, replace the cylinder block.
Surface warpage limit: 0.02 mm (0.0008 in)
Standard height of cylinder block: 202 mm (7.95 in)
CYLINDER AND PISTON
1) The cylinder bore size is stamped on the front upper face of the cylinder block.
NOTE:
- Measurement should be performed at a temperature of 20 degrees C (68 degrees 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.
Standard diameter.
A: 92.005 - 92.015 mm (3.6222 - 3.6226 in)
B: 91.995 - 92.005 mm (3.6218 - 3.6222 in)
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 degrees C (68 degrees F).
Cylindricality:
Standard: 0.030 mm (0.0012 in)
Out-of-roundness: Standard. 0.010 mm (0.0004 in)
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 degrees C (68 degrees F).
Piston grade point H: 37.3 mm (1.4685 in)
Piston outer diameter:
Standard:
A: 92.005 - 92.015 mm (3.6222 - 3.6226 in)
B: 91.995 - 92.005 mm (3.6218 - 3.6222 in)
0.25 mm (0.0098 in) oversize: 92.245 - 92.265 mm (3.6317 - 3.6325 in)
0.50 mm (0.0197 in) oversize: 92.495 - 92.515 mm (3.6415 - 3.6423 in)
5) Calculate the clearance between cylinder and piston.
NOTE:
Measurement should be performed at a temperature of 20 degrees C (68 degrees F).
Cylinder to piston clearance at 20 degrees C (68 degrees F):
Standard: -0.010 - 0.010 mm (-0.0004 - 0.0004 in)
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 92.515 mm (3.6317 in) after boring and honing, replace the cylinder block.
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 faulty.
2) Measure the clearance between each cylinder piston and cylinders. If any of the clearances is not within standard, replace the piston, or bore the cylinder to use an oversize piston.
3) Check that the piston pin can be inserted into the piston pin hole just by using your thumb at 20 degrees C (68 degrees F). Replace if faulty.
Standard clearance between piston pin and hole in piston:
Standard: 0.004 - 0.008 mm (0.0002 - 0.0003 in)
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 part of the same size as piston.
CAUTION:
- Marks are displayed on the end of top and second rings. When installing the ring to piston, face this mark upward.
- Oil ring consists of the upper rail, expander and lower rail. When installing on the piston, be careful of the direction of each rail
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 thrust clearance. If the clearance exceeds the standard or offset wear occurs, replace the connecting rod.
Connecting rod thrust clearance:
Standard: 0.070 - 0.330 mm (0.0028 - 0.0130 in)
4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the table below.)
Connecting rod oil clearance:
Standard: 0.016 - 0.043 mm (0.0006 - 0.0017 in)
6) Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance on the smaller end of the connecting rod.
Clearance between piston pin and bushing:
Standard: 0 - 0.022 mm (0 - 0.0009 in)
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 the new bushing.
ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER
(3) Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the pre-manufactured holes on the connecting rod. 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. Repair or replace if bent.
NOTE:
If a suitable V-block is not available, install #1 and #7 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then check the crankshaft bend using a dial gauge.
3) Inspect the crank journal and crank pin for wear. If they are not within the specification, replace the bearing with a suitable (undersize) one, and replace or readjust 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.
Crank pin and crank journal:
Out-of-roundness: 0.005 mm (0.0002 in)
Cylindricality: 0.006 mm (0.0002 in)
4) Use a thickness gauge to measure the thrust clearance of crankshaft at center bearing. If clearance exceeds the standard, replace the bearing.
Crankshaft thrust clearance:
Standard: 0.030 - 0.115 mm (0.0012 - 0.0045 in)
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary.
Crankshaft oil clearance:
Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in)