Cylinder Block Assembly: Service and Repair
REMOVAL
1. Remove engine assembly from body as previously outlined.
2. Remove clutch cover, clutch disc and flywheel (drive plate for A/T).
Special Tool (A): 09924-17810
3. Remove crankshaft pulley, timing belt and crankshaft timing pulley.
4. Remove cylinder head assembly.
5. Remove oil pan and oil pump strainer.
6. Remove oil pump.
7. Remove oil seal housing.
8. Remove connecting rod bearing caps.
9. Loosen crankshaft bearing cap bolts in such order as indicated in figure a little at a time and remove bearing caps.
10. Remove crankshaft from cylinder block.
INSPECTION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft.
Limit on runout: 0.06 mm (0.0023 inch)
Crankshaft thrust play
Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed.
Use a dial gauge to read displacement in axial (thrust) direction of crankshaft.
If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard thrust play.
Out-Of-Round And Taper (Uneven Wear) Of Journals
An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This difference, if any, is determined by taking micrometer readings.
If any one of journals is badly damaged or if amount of uneven wear in the sense explained above exceeds its limit, regrind or replace crankshaft.
Limit on out-of-round and taper: 0.01 mm (0.004 inch)
Main Bearings
General information
- Service main bearings are available in standard size and 0.25 mm (0.0098 inch) undersize, and each of them has 5 kinds of bearings differing in tolerance.
- Upper half of bearing has oil groove as shown in figure. Install this half with oil groove to cylinder block.
- On each main bearing cap, arrow mark and number are embossed as shown in figure.
When installing each bearing cap to cylinder block, point arrow mark toward crankshaft pulley side and install each cap from that side to flywheel side in ascending order of numbers "1", "2", "3", "4" and "5". Tighten cap bolts to specified torque.
Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves. Never replace one half without replacing the other half.
Main bearing clearance
Check clearance by using gaging plastic according to following procedure.
1. Remove bearing caps.
2. Clean bearings and main journals.
3. Place a piece of gaging plastic the full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
4. Install bearing cap as previously outlined and evenly torque cap bolts to specified torque.
Bearing cap MUST be torqued to specification in order to assure proper reading of clearance.
Tightening Torque (a): 54 Nm (39.0 ft. lbs.)
NOTE: Do not rotate crankshaft while gaging plastic is installed.
5. Remove cap and using scale on gaging plastic envelope, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit.
A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use of 0.25 mm undersize bearing.
After selecting new bearing, recheck clearance.
Selection of main bearings
STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to following procedure and install it.
1. First check journal diameter by using following procedure. As shown in figure, crank webs of No.2 and No.3 cylinders have five stamped numerals.
Three kinds of numerals ("1", "2" and "3") represent following journal diameters.
The first, second, third, fourth and fifth (left to right) stamped numerals represent journal diameters at bearing caps "1", "2", "3", "4" and "5" respectively.
For example, in figure, the first (left-most) numeral "3" indicates that journal diameter at bearing cap " 1 " is within 51.982 - 51.988 mm, and second one "1 " indicates that journal diameter at cap "2" is within 51.994 - 52.000 mm.
2. Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, four alphabets are stamped as shown in figure.
Three kinds of alphabets ("A", "B" and "C") represent following cap bore diameters.
The first, second, third, fourth and fifth (left to right) stamped alphabets represent cap bore diameters of bearing caps "1", "2", "3", "4" and "5", respectively.
For example, in figure, the first (left-most) alphabet "B" indicates that cap bore diameter of bearing cap "1 " is within 56.006 - 56.012 mm, and the fifth (right-most) alphabet "A" indicates that cap bore diameter of cap "5" is within 56.000 - 56.006 mm.
3. There are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in following colors at the position as indicated in figure.
Each color indicates following thickness at the center of bearing.
4. From numerals stamped on crank webs of No.2 and No.3 cylinders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to journal, by referring to table.
For example, if numeral stamped on crank web is "1" and alphabet stamped on mating surface is "B", install a new standard bearing painted in "Black" to its journal.
5. Using gaging plastic, check bearing clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
6. When replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by referring to numerals stamped on new crankshaft or alphabets stamped on mating surface of new cylinder block.
UNDERSIZE BEARING (0.25 mm):
- 0.25 mm undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in following colors at such position as indicated in figure.
Each color represents following thicknesses at the center of bearing.
- If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
1. Regrind journal to following finished diameter.
Finished diameter: 51.732 - 51.750 mm (2.0367 - 2.0373 inch)
2. Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
3. Using journal diameter measured above and alphabets stamped on mating surface of cylinder block, select an undersize bearing by referring to table given.
Check bearing clearance with newly selected undersize bearing.
Rear Oil Seal
Carefully inspect oil seal for wear or damage. If its lip is worn or damaged, replace it.
For oil seal installation, press-fit rear oil seal so that oil seal housing end face is flush with oil seal end face.
Flywheel
- If ring gear is damaged, cracked or worn, replace flywheel.
- If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.
- Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 inch)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it.
Honing Or Rebating Cylinders
1. When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2. Select oversized piston according to amount of cylinder
3. Using micrometer, measure piston diameter.
4. Calculate cylinder bore diameter to be rebored.
D = A + B - C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
C: Allowance for honing = 0.02 mm (0.0008 inch)
5. Rebore and hone cylinder to calculated dimension.
NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores.
6. Measure piston clearance after honing.
INSTALLATION
NOTE:
^ All parts to be installed must be perfectly clean.
^ Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores.
^ Journal bearings, bearing caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.
1. Install main bearings to cylinder block.
One of two halves of main bearing, has an oil groove. Install it to cylinder block, and the other half without oil groove to bearing cap.
Make sure that two halves are painted in the same color.
2. Install thrust bearings to cylinder block between No.2 and No.3 cylinders. Face oil groove sides to crank webs.
3. Install crankshaft to cylinder block.
4. Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3, 4 and 5 starting from pulley side. After installing bearing cap stiffeners, tighten bearing cap bolts in such order as shown in figure a little at a time and repeat it till they are tightened to specified torque.
Tightening Torque (a): 54 Nm (39.0 ft. lbs.)
NOTE: After tightening cap bolts, check to be sure that crankshaft rotates smoothly when turning it by 8.0 Nm (5.8 ft. lbs.) torque or below.
5. Install new gasket and oil seal housing. Do not reuse gasket removed in disassembly. Apply engine oil to oil seal lip before installation. Tighten housing bolts to specification.
Tightening Torque (a): 11 Nm (8.0 ft. lbs.)
NOTE: As there are 2 types of housing bolts, refer to figure for their correct use.
After installing oil seal housing, gasket edges might bulge out; if so, cut them off to make them flush with cylinder block and oil seal housing.
6. Install oil pump.
Refer to item "Oil pump" for installation of oil pump.
7. Install flywheel (M/T model) or drive plate (A/T model). Using special tool, lock flywheel or drive plate, and torque its bolts to specification.
Special Tool (A): 09924-1 7810
Tightening Torque
(a): 78 Nm (56.5 ft. lbs.) (Flywheel bolts)
(a): 95 Nm (69.0 ft. lbs.) (Drive plate bolts)
8. Install pistons and connecting rods as previously outlined.
9. Install oil pump strainer and oil pan as previously outlined.
10. Install cylinder head assembly to cylinder block as previously outlined.
NOTE: Tighten cylinder head bolts to specified torque as previously outlined. Whenever installing cylinder head to new cylinder block, use following procedure to tighten cylinder head bolts.
^ Tighten cylinder head bolts to specified torque as previously outlined and loosen them once till tightening torque becomes "zero". And then torque them to specification again.
11. Install camshaft, crankshaft timing belt pulley, timing belt, crankshaft pulley, water pump pulley, etc., as previously outlined.
12. Install clutch to flywheel (for M/T vehicle). For clutch installation, refer to CLUTCH.
13. Install engine mountings and brackets.
Tightening Torque
(a): 55 Nm (40.0 ft. lbs.)
(b): 45 Nm (32.5 ft. lbs.)
14. Install engine assembly to vehicle as previously outlined.