Part 1 of 2
Disassembly
1. M/T : remove the flywheel.
2. A/T : remove the drive plate.
3. Install the engine to the engine stand for disassembly.
4. Remove the timing chain.
5. Remove the cylinder head.
6. Remove the alternator(A) from engine.
7. Remove the tensioner assembly integrated bracket(A).
8. Remove the knock sensor(A).
9. Remove the water pump.
10. Remove the oil pump.
11. Remove the ladder frame(A).
12. Check the connecting rod end play.
13. Remove the connecting rod caps and check oil clearance.
14. Remove the piston and the connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.
15. Remove the crankshaft bearing cap and check oil clearance.
16. Check the crankshaft end play.
17. Lift the crankshaft(A) out of the engine, being careful not to damage journals.
NOTE:
Arrange the main bearings and thrust bearings in the correct order.
18. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
19. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove 2 side rails and the spacer by hand.
NOTE:
Arrange the piston rings in the correct order only.
20. Disconnect the connecting rod from piston.
Inspection
Connecting Rod And Crankshaft
1. Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play :0.1 - 0.25mm(0.004 - 0.010in.)
Maximum end play :0.35mm(0.0138in.)
A. If out-of-tolerance, install a new connecting rod.
B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.4lb-ft) + 90°
NOTE:
Do not turn the crankshaft.
(7) Remove 2 bolts, connecting rod cap and bearing half.
(8) Measure the plastigage at its widest point.
Standard oil clearance
0.025 - 0.043mm(0.0009 - 0.0016in.)
(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
CAUTION:
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
NOTE:
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
CAUTION:
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Connecting Rod Mark Location
NOTE:
Prevention mark (A) of cap directions should be assembled toward the front of the engine.
Discrimination Of Connecting Rod
Crankshaft Pin Mark Location Discrimination Of Crankshaft
NOTE:
Conform to read stamping order as shown arrow direction from #1.
Discrimination Of Crankshaft
Place Of Identification Mark (Connecting Rod Bearing) Discrimination Of Connecting Rod Bearing
Discrimination Of Connecting Rod Bearing
(11) Selection
3. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
14.7Nm (1.5kgf.m, 10.8lb-ft) + 29.4Nm (3.0kgf.m, 21.6lb-ft) + 120°
NOTE:
Do not turn the crankshaft.
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.020 - 0.038mm (0.0008 - 0.0015in.)
(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
CAUTION:
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
NOTE:
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
CAUTION:
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Connecting Rods
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod :
0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039 in./3.94 in.) or less
Crankshaft bore mark location
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
Discrimination Of Cylinder Block
Crankshaft Journal Mark Location Discrimination Of Crankshaft
NOTE:
Conform to read stamping order as shown arrow direction from #1.
Discrimination Of Crankshaft
Place Of Identification Mark (Crankshaft Bearing) Discrimination Of Crankshaft Bearing
Discrimination Of Crankshaft Bearing
Selection
4. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play
0.07 - 0.25mm (0.0027 - 0.0098in.)
Limit : 0.30mm (0.0118in.)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness
1.925 - 1.965mm(0.0758 - 0.07736in.)
5. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
51.942 - 51.960mm (2.0449 - 2.0456in.)
Crank pin diameter :
47.954 - 47.972mm (1.8879 - 1.8886in.)
Cylinder Block
1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05mm(0.0020 in.)
4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter
86.00 - 86.03mm (3.3858 - 3.3870in.)
NOTE:
Measure position(from the bottom of the cylinder block)
: 110.7mm(4.3582in.) / 160mm (6.2992in.) / 210mm (8.2677in.)
6. Check the cylinder bore size code on the cylinder block.
Cylinder Bore Inner Diameter
7. Check the piston size code on the piston top face.
NOTE:
Stamp the grade mark of basic diameter with rubber stamp.
Piston Outer Diameter
8. Select the piston related to cylinder bore class.
Clearance :0.015 - 0.035mm (0.00059 - 0.00137in.)