Part 1
Cylinder BlockASSEMBLY (Part 1)
CYLINDER BLOCK
1) Apply liquid gasket to the threaded portion of the main gallery plug, and install the main gallery plug to the cylinder block LH.
NOTE:
Before applying liquid gasket, degrease the thread holes of the cylinder block LH and main gallery plug.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or equivalent
Tightening torque:
37 Nm (3.8 kgf-m, 27.3 ft-lb)
2) Install the cylinder block plate onto cylinder block LH.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
3) Apply liquid gasket to the threaded portions of cylinder block plug and main gallery plug, and install the cylinder block plug (A) and main gallery plug (B) to cylinder block RH.
NOTE:
Before applying liquid gasket, degrease the thread holes of the cylinder block RH, and the threaded portions of cylinder block plug and main gallery plug.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or equivalent
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 37 Nm (3.8 kgf-m, 27.3 ft-lb)
4) Install the oil separator cover to the cylinder block RH.
(1) Apply liquid gasket to the mating surfaces of oil separator cover.
NOTE:
^ Use new oil separator cover.
^ Before applying liquid gasket, degrease the old liquid gasket seal surface of cylinder block RH.
^ Install within 5 min. after applying liquid gasket.
Liquid gasket:
Mating surface
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Liquid gasket applying diameter:
4±1 mm (0.1772±0.0197 in)
(2) Install the oil separator cover to the cylinder block RH, and tighten the oil separator cover bolts in numerical order as shown in the figure.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
5) Install the water jacket spacer to the cylinder block RH and cylinder block LH. (XV model)
PISTON AND CONNECTING ROD
1) Install the connecting rod bearing to the connecting rod and connecting rod cap.
2) Install the circlip on one end of the piston using a flat tip screwdriver.
NOTE:
^ Be careful not damage the piston, by wrapping the tip of flat tip screwdriver with tape.
^ Make sure the circlip is firmly inserted into the circlip groove.
^ After installing the circlip, rotate the circlip so that its end part (a) and the cutout portion of circlip groove (b) do not match.
3) Set the piston to the connecting rod.
NOTE:
Align the front mark of piston and the connecting rod direction correctly as shown in the figure.
4) Apply engine oil to the piston pin, and attach the piston pin.
5) Install the circlip on the piston using a flat tip screwdriver.
NOTE:
^ Be careful not damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape.
^ Make sure the circlip is firmly inserted into the circlip groove.
^ After installing the circlip, rotate the circlip so that its end part (a) and the cutout portion of circlip groove (b) do not match.
6) Install the piston rings onto the piston.
(1) Install the oil rings in the order of expander, lower rail and upper rail by hand.
NOTE:
Oil ring consists of the upper rail, expander and lower rail.
(2) Install the compression rings in the order of second ring and top ring, using piston ring expander.
NOTE:
Install so that the compression ring mark faces the top side of the piston.
INSPECTION
CYLINDER BLOCK & PISTON
1) Visually inspect to make sure that there are no cracks, scratches or other damage.
2) Use liquid penetrant tester on the important sections to check for fissures.
3) Check that there are no traces of gas leaking or water leaking on the gasket attachment surface.
4) Check the oil passages for clogging.
5) Check for warpage of mating surfaces of the cylinder block that contacts cylinder head using a straight edge and thickness gauge. If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder block.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Cylinder block warpage:
Limit
0.025 mm (0.00098 in)
Grinding limit of cylinder block :
To 204.9 mm (8.067 in)
Height of cylinder block:
Standard
205.0 mm (8.071 in)
6) Using a cylinder bore gauge, check the inner diameter of cylinder liner, cylindricality, out-of-roundness. If it is not within the standard, perform boring and honing, or replace the cylinder block and piston as a set. For boring and honing procedure, refer to step 8).
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Measure the inner diameter of each cylinder liner in both the thrust and piston pin directions at the heights as shown in the figure.
^ The cylinder bore size mark is stamped on the upper face of the cylinder block.
Inner diameter of cylinder liner:
Cylinder bore size mark A
Standard
84.005 - 84.015 mm (3.3073 - 3.3077 in)
Cylinder bore size mark B
Standard
83.995 - 84.005 mm (3.3069 - 3.3073 in)
Cylindricality of cylinder liner:
Limit
0.015 mm (0.0006 in)
Out-of-roundness of cylinder liner:
Limit
0.010 mm (0.0004 in)
7) Check the clearance between cylinder liner and piston. Check the clearance between cylinder liner and piston by measuring the inner diameter of cylinder liner and the outer diameter of piston respectively.
NOTE:
For the measurement of the inner diameter of cylinder liner, refer to step 6).
(1) Check the outer diameter of piston with a micrometer. If it is not within the standard, replace the piston.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Measure the outer diameter of each piston in thrust direction at the height as shown in the figure.
^ Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston.
^ If the piston is replaced, check the clearance between cylinder liner and piston in the step (2), and select a suitable sized piston.
Piston grade point H:
38.0 mm (1.50 in)
Piston outer diameter:
Standard size (grade A)
Standard
83.975 - 83.985 mm (3.3061 - 3.3065 in)
Standard size (grade B)
Standard
83.965 - 83.975 mm (3.3057 - 3.3061 in)
0.25 mm (0.0098 in) oversize
Standard
84.215 - 84.235 mm (3.3155 - 3.3163 in)
0.50 mm (0.0197 in) oversize
Standard
84.465 - 84.485 mm (3.3254 - 3.3262 in)
(2) Calculate the clearance between cylinder liner and piston. If it is not within the standard, perform boring and honing, or replace the cylinder block and piston as a set. For boring and honing procedure, refer to step 8).
Clearance between cylinder liner and piston:
Standard
0.020 - 0.040 mm (0.00079 - 0.00157 in)
8) Boring and honing
(1) If any of the inner diameter, cylindricality, out-of-roundness or clearance between cylinder liner and piston is out of standard or if there is any damage on the cylinder liner, rebore it to replace with an oversize piston.
CAUTION:
When any of the cylinder liner needs reboring, all other cylinder liners must be bored at the same time, and replaced with oversize pistons.
(2) If the inner diameter of cylinder liner exceeds the limit after boring and honing, replace the cylinder block and piston as a set.
NOTE:
^ Immediately after reboring, the inner diameter of cylinder liner may differ from its real diameter due to temperature rise. Thus, when measuring the inner diameter of cylinder liner, wait until the temperature has cooled to 20°C (68°F).
^ For the measurement of the inner diameter of cylinder liner, refer to step 6).
Inner diameter of cylinder liner boring limit (diameter):
To 84.505 mm (3.3270 in)
PISTON AND PISTON PIN
1) Check the piston and piston pin for wear or crack.
2) Check the snap ring for distortion or wear.
3) Check the piston ring groove for damage.
4) Check the circlip groove (A) for burr.
NOTE:
If the burr is found, remove the burr from groove.
5) Check that the piston pin can be inserted into the piston with a thumb at 20°C (68°F).
6) Check the clearance between piston and piston pin. Check the clearance between piston and piston pin by measuring the inner diameter of piston pin hole and the outer diameter of piston pin respectively.
(1) Using a caliper gauge, measure the inner diameter of piston pin hole.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Measure the inner diameter of the piston pin hole at the four locations as shown in the figure, and read the value of most worn location.
^ Record the measured value.
(2) Measure the outer diameter of piston pin with a micrometer.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Measure the outer diameter of the piston pin at the four locations as shown in the figure, and read the value of most worn location.
^ Record the measured value.
(3) Calculate the clearance between piston and piston pin. If it is not within the standard, replace the piston and piston pin as a set.
Clearance between piston and piston pin:
Standard
0.004 - 0.008 mm (0.0002 - 0.0003 in)
PISTON RING
1) Make sure the piston ring is not broken or damaged.
2) Using a cylindrical guide, insert the piston ring into the cylinder liner so that they are perpendicular to the cylinder wall, and check the piston ring gap using a thickness gauge. If it is not within the standard, replace the piston ring.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Use piston ring with same size as piston when replacing piston ring.
Piston ring gap:
Compression ring (top ring)
Standard
0.20 - 0.35 mm (0.0079 - 0.0138 in)
Compression ring (second ring)
Standard
0.40 - 0.50 mm (0.0157 - 0.0197 in)
Oil ring (upper rail and lower rail)
Standard
0.20 - 0.50 mm (0.0079 - 0.0197 in)
3) Fit the compression ring straight into the piston ring groove, then check the clearance between compression ring and piston with a thickness gauge. If it is not within the standard, replace the compression ring.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Before inspecting the clearance, clean the piston ring groove and compression ring.
^ Use compression ring with same size as piston when replacing compression ring.
Clearance between compression ring and piston:
Top ring
Standard
0.040 - 0.080 mm (0.0016 - 0.0031 in)
Second ring
Standard
0.030 - 0.070 mm (0.0012 - 0.0028 in)
CONNECTING ROD AND CONNECTING ROD BEARING
1) Check for bend or twist using a connecting rod aligner. If it exceeds the limit, replace the connecting rod.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Bend or twist per 100 mm (3.94 in) in length:
Limit
0.10 mm (0.0039 in)
2) Check that the large or small end thrust surface of each connecting rod is not damaged.
3) Check each connecting rod bearing for scar, peeling, seizure, melting or wear, etc.
4) Check the thrust clearance of each connecting rod using a thickness gauge.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
(1) Clean the #1 connecting rod bearing and the #1 pin of crankshaft, and apply engine oil to the #1 pin of crankshaft.
(2) Set the #1 connecting rod bearing to the #1 connecting rod and #1 connecting rod cap.
(3) Set the #1 connecting rod, #1 connecting rod cap and #1 connecting rod cap bolt to the #1 pin of crankshaft.
NOTE:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
^ Use a new connecting rod cap bolt.
^ Apply a coat of engine oil to the #1 connecting rod cap bolt thread.
(4) Using ST, tighten the #1 connecting rod cap bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 Nm (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
CAUTION:
^ Make sure to hold the crankshaft securely during work.
^ When holding the crankshaft, be careful not to damage the crankshaft.
ST 18270AA010 SOCKET
(5) Using angle gauge and ST, tighten the #1 connecting rod cap bolts with specified angle in numerical order as shown in the figure.
CAUTION:
^ Make sure to hold the crankshaft securely during work.
^ When holding the crankshaft, be careful not to damage the crankshaft.
ST 18270AA010 SOCKET
Tightening angle:
137°±2°
(6) In the same manner, install the #2, #3 and #4 connecting rods.
(7) Check the thrust clearance of each connecting rod using a thickness gauge. If it is not within the standard, replace the connecting rod.
NOTE:
Measure the thrust clearance of each connecting rod at several points, and replace the connecting rod if there is uneven wear.
Connecting rod thrust clearance:
Standard
0.070 - 0.330 mm (0.0028 - 0.0130 in)
5) Check the oil clearance on each connecting rod bearing using Plastigauge(R).
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
(1) Clean the #1 connecting rod bearing and the #1 pin of crankshaft.
(2) Set the #1 connecting rod bearing to the #1 connecting rod and #1 connecting rod cap.
(3) Place a Plastigauge(R) across the #1 pin of crankshaft, and set the #1 connecting rod, #1 connecting rod cap and #1 connecting rod cap bolt to the #1 pin of crankshaft.
NOTE:
^ Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
^ Use a new connecting rod cap bolt.
^ Apply a coat of engine oil to the #1 connecting rod cap bolt thread.
(4) Using ST, tighten the #1 connecting rod cap bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 Nm (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
CAUTION:
^ Make sure to hold the crankshaft securely during work.
^ When holding the crankshaft, be careful not to damage the crankshaft.
^ During tightening, be careful not to move the #1 connecting rod and the #1 connecting rod cap.
ST 18270AA010 SOCKET
(5) Using angle gauge and ST, tighten the #1 connecting rod cap bolts with specified angle in numerical order as shown in the figure.
CAUTION:
^ Make sure to hold the crankshaft securely during work.
^ When holding the crankshaft, be careful not to damage the crankshaft.
^ During tightening, be careful not to move the #1 connecting rod and the #1 connecting rod cap.
ST 18270AA010 SOCKET
Tightening angle:
137°±2°
(6) Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.
CAUTION:
^ Make sure to hold the crankshaft securely during work.
^ When holding the crankshaft, be careful not to damage the crankshaft.
^ During removal, be careful not to move the #1 connecting rod and the #1 connecting rod cap.
ST 18270AA010 SOCKET
(7) Determine oil clearance of the #1 connecting rod bearing by matching the widest point of the Plastigauge(R) on #1 pin of crankshaft against scale printed on a package of the Plastigauge(R). If it is not within the standard, replace the #1 connecting rod bearing.
NOTE:
Measure the outer diameter of crankshaft pin using micrometer, and select the suitable size connecting rod bearing when replacing the connecting rod bearing.
Connecting rod bearing oil clearance:
Standard
0.017 - 0.047 mm (0.0007 - 0.0019 in)
(8) Completely remove the Plastigauge(R).
(9) In the same manner, check oil clearance of the #2, #3 and #4 connecting rod bearings.