Disassembly and Assembly
Disassembly and Assembly
CAUTION:
^ Apply new engine oil to parts as marked in illustrations before installation.
^ Place removed parts such as bearings and bearing caps in their proper order and direction.
^ When installing the connecting rod nuts, and main bearing cap bolts, apply new engine oil to the threads and mating surfaces
^ Do not allow any magnetic materials to contact the signal plate teeth on the drive plate.
DISASSEMBLY
1. Remove the engine assembly.
2. Install the engine on the engine stand.
3. Remove the knock sensor.
CAUTION: Carefully handle sensor avoiding shocking it.
4. Drain the engine of all coolant and oil.
5. Remove the oil pan.
6. Remove the timing chain.
7. Remove the cylinder.
8. Remove drive plate. Fix crankshaft with a ring gear stopper, and remove mounting bolts.
^ Loosen mounting bolts in diagonal order.
CAUTION:
^ Do not disassemble drive plate.
^ Never place the drive plate with signal late facing down.
^ When handling signal plate, take care not to damage or scratch it.
^ Handle signal plate in a manner that prevents it from becoming magnetized.
9. Remove pilot bushing (M/T) or converter (A/T) using Tool.
10. Use a seal cutter to cut away liquid gasket and remove rear oil seal retainer.
CAUTION:
^ Be careful not to damage mounting surface.
^ If rear oil seal retainer is removed, replace it with a new one.
NOTE: Rear oil seal and retainer form a single part and are handled as an assembly.
11. Remove the piston and connecting rod assemblies.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and connecting rod assembly out to the cylinder head side.
^ Before removing the piston and connecting rod assembly, check the connecting rod side clearance.
12. Remove the connecting rod bearings.
CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order.
13. Remove the piston rings from the piston.
^ Use a piston ring expander.
CAUTION:
^ When removing the piston rings, be careful not to damage the piston. Do not expand the rings excessively.
^ Be careful to mark the rings if they are to be reused so they are installed in their original position.
^ Before removing the piston rings, check the piston ring side clearance.
14. Remove the piston from the connecting rod as follows.
a. Using a snap ring pliers, remove the snap ring.
b. Heat the pistons to 60° - 70°C (140° - 158°F).
c. Push out the piston pin with a suitable tool, with an outer diameter approximately 20 mm (0 8 inch)
15. Remove the rear oil seal retainer from the cylinder block.
^ Insert a screwdriver or similar tool between the rear end of the crankshaft counter weight and rear oil seal retainer, and separate the liquid gasket to remove.
CAUTION: Be careful not to damage the mating surface.
NOTE: When replacing the rear oil seal during on-vehicle service, it is necessary to remove the oil pan.
16. Loosen the bolts in the numerical order as shown and remove the main bearing beam, bearing caps and crankshaft.
^ Before loosening the main bearing cap bolts, measure the crankshaft side clearance.
17. Remove the oil jets.
18. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.
^ When removing them, note the direction and position. Keep them in the correct order for installation.
ASSEMBLY
1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials.
CAUTION: Use goggles to protect your eyes.
2. Apply liquid gasket and install each plug into the cylinder block.
^ Use Genuine Silicone RTV Sealant or equivalent.
3. Install the oil jets.
^ Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the mounting bolts.
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
b. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.
^ Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
^ Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.
5. Set the upper main bearings in their proper positions on the cylinder block.
^ Confirm the correct main bearings are used.
6. Instructions for the re-use of the main bearing cap bolts.
^ A plastic zone tightening method is used for tightening the main bearing cap bolts. Measure d1 and d2 as shown.
^ For d2, select the minimum diameter in the measuring area.
^ If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.
Limit (d1 - d2): 0.11 mm (0.0043 inch)
7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts. Tighten the bearing cap bolts in the numerical order shown.
a. Make sure that the front marks on the main bearing beam faces the front of the engine.
b. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
c. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
d. Lubricate the threads and seat surfaces of the bolts with new engine oil.
e. Tighten the bolts in two stages:
CAUTION: Measure the tighten angle in stage 2 with an angle wrench. Do not measure visually.
Stage 1: 32 - 38 Nm (3.3 - 3.9 kg-m, 24 - 28 ft. lbs.)
Stage 2: 90° - 95° degrees clockwise
8. Measure crankshaft end play.
If beyond the limit, replace the bearing with a new one.
Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit: 0.30 mm (0.0118 inch)
9. Install the rear oil seal retainer.
^ Apply sealant to rear oil seal retainer as shown.
Use Genuine Silicone RTV Sealant, or equivalent.
Rear oil seal retainer: 8.2 - 9.3 Nm (0.83 - 0.95 kg-m, bolts 72 - 82 inch lbs.)
10. Install the piston to the connecting rod.
a. Using suitable snap ring pliers, install the snap ring into the pin groove of the piston rear side.
^ Insert it fully into groove to install.
b. Install the piston to the connecting rod.
^ Heat the piston until the piston pin can be pushed in by hand without excess force [approximately 60° - 70°C (140° to 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.
^ Assemble so that the front mark on the piston crown and the oil holes and the cylinder No. on the connecting rod are positioned as shown.
c. Install the snap ring into the front of the piston pin-groove.
^ After installing, check that the connecting rod pivots smoothly on the pin.
11. Using a piston ring expander, install the piston rings.
CAUTION:
^ Be careful not to damage the piston.
^ When the piston rings are not replaced, remount the rings in their original positions.
^ When replacing the piston rings, those without punchmarks can be mounted either side up.
^ Position each ring with the gap as shown, referring to the piston front mark.
^ Install the top ring and the second ring with the stamped surface facing upward. If the ring is not stamped it can face in either direction.
12. Install the connecting rod bearings to the connecting rod and the connecting rod cap.
^ When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it.
^ When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install.
^ Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.
13. Install the piston and connecting rod assembly into the corresponding cylinder.
^ Position the crankshaft pin corresponding to the connecting rod to be installed onto the bottom dead center.
^ Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
^ Match the cylinder No. on the connecting rod to install.
^ Using a piston ring compressor, install the piston with the front mark on the piston crown facing the front of the engine.
CAUTION: Be careful not to damage the crankshaft pin and cylinder wall, resulting from an interference of the connecting rod big end.
14. Install the connecting rod cap.
^ Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
^ Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine.
Lubricate the threads and seat surfaces with new engine oil.
15. Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand.
^ Measure the outer diameter of the connecting rod cap bolt as shown.
Outer diameter "d" of the connecting rod bolt
Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit: 7.75 mm (0.3051 inch)
16. Tighten the connecting rod nuts in two stages:
Stage 1: 19 - 21 Nm (1.9 - 2.1 kg-m, 14 -15 ft. lbs.)
Stage 2: 90° - 95° degrees clockwise
CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.
^ Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
^ After tightening the nuts, make sure that the crankshaft rotates smoothly.
^ Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft.
Connecting rod side clearance:
Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit: 0.40 mm (0.0157 inch)
17. Install the knock sensor.
^ Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
^ Install the knock sensor with the connector facing the rear of the engine.
^ Do not tighten the mounting bolts while holding the connector.
^ Make sure that the knock sensor does not interfere with other parts.
CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
Knock sensor mounting: 16 - 26 Nm (1.6 - 2.7 kg-m, bolt 12 - 20 inch lbs.)
18. Install the pilot bushing (M/T) or converter (A/T) as shown.
19. Install the flywheel (M/T), if equipped.
^ When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.
Flywheel mounting bolts: 83 - 93 Nm (8.5 - 95 kg-m, 61 - 69 ft. lbs.)
20. Install the drive plate (A/T), if equipped.
^ Install the drive plate and reinforce plate in the direction shown.
^ Align dowel pins of crankshaft rear and drive plate with pin holes of each part.
^ Secure the crankshaft using a ring gear stopper.
^ Tighten the drive plate mounting bolts in one or two steps.
Drive plate mounting bolts: 83 - 93 Nm (8.5 - 95 kg-m, 61 - 69 ft. lbs.)
21. Install the cylinder.
22. Install the timing chain.
23. Install the oil pan.
24. Remove the engine from the stand and install the engine assembly into the vehicle.
25. Assembly of the remaining parts is in the reverse order of disassembly.
26. Fill the engine with the specified oil and coolant.
CAUTION: Wait at least 30 minutes for the sealant to set-up before filling the engine with fluids and running it.