Cylinder Block Assembly: Service and Repair
CAUTION:
- When installing bearings, pistons, or other sliding parts, lubricate contacting surfaces with new engine oil.
- Place removed parts such as bearings and bearing caps in their proper order and direction.
- When installing connecting rod nuts, and main bearing cap bolts, apply new engine oil to threads and seating surfaces.
- Do not allow any magnetic materials to contact the signal plate teeth of flywheel or drive plate.
Disassembly
PISTON AND CRANKSHAFT
1. Remove engine.
Exploded view of work stand w/ torque values
Work stand w/ engine
2. Place engine on a work stand.
3. Drain coolant and oil.
4. Remove oil pan.
5. Remove timing chain.
6. Remove cylinder head.
7. Remove pistons with connecting rods.
- When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F).
8. Remove rear oil seal retainer.
CAUTION:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When replacing piston rings, if there is no punchmark, install with either side up.
9. Loosen bolts in numerical order as shown and remove main bearing beam, bearing cap and crankshaft.
- Before removing bearing beam and bearing cap, 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":
Grade No.0 21.993 - 21.999 mm (0.8659 - 0.8661 inch)
Grade No.1 21.999 - 22.005 mm (0.8661 - 0.8663 inch)
2. Measure outer diameter of piston pin "Dp".
Standard diameter "Dp":
Grade No.0 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No.1 21.995 - 22.001 mm (0.8659 - 0.8662 inch)
3. Calculate interference fit of piston pin to piston.
Dp - dp = 0.002 - 0.06 mm (0.0001 - 0.0024 inch)
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 inch)
2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Oil ring 0.015 - 0.185 mm (0.0006 - 0.0073 inch)
Maximum limit of side clearance:
Top ring 0.11 mm (0.0043 inch)
2nd ring 0.1 mm (0.004 inch)
If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston.
PISTON RING END GAP
End gap:
Top ring 0.22 - 0.32 mm (0.0087 - 0.0126 inch)
2nd ring 0.32 - 0.47 mm (0.0126 - 0.0185 inch)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 inch)
Maximum limit of ring gap:
Top ring 0.55 mm (0.0217 inch)
2nd ring 0.85 mm (0.0335 inch)
Oil ring 0.95 mm (0.0374 inch)
If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. 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 inch) per 100 mm (3.94 inch) length
Torsion:
Limit 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length
If it exceeds the limit, replace connecting rod assembly.
CYLINDER BLOCK DISTORTION AND WEAR
- Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface.
Check along six positions shown in the figure.
Distortion limit: 0.10 mm (0.0039 inch)
- If out of specification, resurface it. The limit for cylinder block resurfacing 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 inch)
Nominal cylinder block height from crankshaft center: 214.95 - 215.05 mm (8.4626 - 8.4665 inch)
- If necessary, replace cylinder block.
PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper.
Cylinder bore inner diameter
If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
Out-of-round (X - Y):
Limit 0.015 mm (0.0006 inch)
Taper (A - B - C):
Limit 0.015 mm (0.0006 inch)
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 rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter.
Piston diameter "A": Refer to Specifications; Mechanical.
Measuring point "a" (Distance from the top): 45.4 mm (1.787 inch)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B": 0.010 - 0.032 mm (0.0004 - 0.0013 inch)
5. Determine piston oversize according to amount of cylinder wear.
Oversize pistons are available for service. Refer to Engine; Specifications; Mechanical.
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 inch)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted 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 inch) 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):
Standard 0.002 mm (0.0001 inch)
Taper (A - B):
Standard 0.002 mm (0.0001 inch)
3. Measure crankshaft runout.
Runout (Total indicator reading): Limit 0.10 mm (0.0039 inch)
BEARING CLEARANCE
- Use either of the following two methods, 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 and bearing beam to cylinder block.
Tighten all bolts in correct order.
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: 0.035 - 0.045 mm (0.0014 - 0.0018 inch) (Actual clearance)
Limit: 0.065 mm (0.0026 inch)
- If it exceeds the limit, replace bearing.
- If clearance cannot be adjusted using any standard bearing grade, 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 inch)
b. For grinding crankshaft and available service parts, refer to Engine; Specifications; Mechanical.
6. If crankshaft or cylinder block is replaced with a new one, 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 Alphabet. If measured diameter is out of grade punched, decide suitable grade using table under Engine; Specifications; Mechanical.
b. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Alphabet. If measured diameter is out of grade punched, decide suitable grade using table under Engine; Specifications; Mechanical.
c. Select main bearing with suitable thickness according to the following table.
For available main bearings, refer to Engine; Specifications; Mechanical.
Main bearing selection table
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 connecting rod.
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 inch) (Actual clearance)
Limit: 0.070 mm (0.0028 inch)
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.
8. If crankshaft is replaced with a new one, select connecting rod bearing according to the following table.
Connecting rod bearing grade number (Identification color):
These numbers are punched in either Arabic or Roman numerals.
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. If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance.
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 - 0.0007 inch)
Limit: 0.030 mm (0.0012 inch)
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. This is to ensure the 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 inch)
DRIVE PLATE RUNOUT
Runout (Total indicator reading) Less than 0.15 mm (0.0059 inch)
CAUTION:
- The signal plate is built into the drive plate assembly. Be careful not to damage the signal plate, especially the teeth.
- Check the drive plate and signal plate for deformation or cracks.
- Keep any magnetized objects away from the signal plate.
- Do not allow any magnetic materials to contact the signal plate teeth.
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 replacing piston rings, these without punchmarks, present, piston rings can be mounted with either side up.
- Align piston rings so that end gaps are positioned as shown in the figure.
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".
2. Instructions for re-use of main bearing cap bolts.
- A plastic zone tightening method is used for tightening main bearing cap bolts. Measure d1 and d2 as shown in the figure.
d2: Select minimum diameter in the measuring area.
If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones.
Limit (d1 - d2): 0.11 mm (0.0043 inch)
3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order as shown.
- Tightening procedure
a) Tighten all bolts to 32 to 38 Nm (3.3 to 3.9 kg-m, 24 to 28 ft. lbs.).
b) Turn all bolts 90 to 95 degrees clockwise with angle wrench.
- Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction.
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
- Lubricate threads and seat surfaces of the bolts with new engine oil.
4. Measure crankshaft end play.
Crankshaft end play:
Standard 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit 0.30 mm (0.0118 inch)
If beyond the limit, replace bearing with a new one.
5. Install connecting rod bearings in connecting rods and connecting rod caps.
- Confirm that correct bearings are used.
6. 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 engine front.
b. A plastic zone tightening method is used for tightening connecting rod bolts and nuts. Check the old bolts for deformation before re-using them.
- Ensure that the connecting rod nut can be screwed smoothly as far as the bolt thread end.
- If this is not possible, use slide calipers to measure the outside diameter of the narrowest thread part of the bolt at 16 mm (0.63 inch) from the thread end. Replace the connecting rod bolt and nut, if under the limit.
Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit: 7.75 mm (0.3051 inch)
c. Install connecting rod caps.
- Lubricate threads and seat surfaces with new engine oil. Tighten connecting rod bearing cap nuts to the specified torque.
Connecting rod bearing nut:
(1) Tighten nuts to 19 to 21 Nm (1.9 to 2.1 kg-m, 14 to 15 ft. lbs.).
(2) Turn nuts 90 to 95 degrees clockwise with angle wrench.
7. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit 0.40 mm (0.0157 inch)
If beyond the limit, replace connecting rod and/or crankshaft.
8. Install rear oil seal retainer.
REPLACING PILOT CONVERTER
1. Remove pilot converter using tool or suitable tool.
2. Install pilot converter as shown.