Part 2 of 2
Piston And Rings1. Clean piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
NOTE:
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.55 in.) from the top land of the piston.
Standard diameter
85.970 - 86.000mm (3.3848 - 3.3860in.)
3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.020 - 0.040mm(0.00078 - 0.00157in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard
No.1 : 0.05 - 0.08mm (0.0019 - 0.0031in.)
No.2 : 0.04 - 0.08mm (0.0015 - 0.0031in.)
Oil ring : 0.06 - 0.14mm (0.0023 - 0.0055in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
If the clearance is greater than maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits, If the bore is over the service limit, the cylinder block must be rebored.
Piston ring end gap
Standard
No.1 : 0.15 - 0.25mm (0.0059 - 0.0098in.)
No.2 : 0.37 - 0.42m (0.0145 - 0.0165in.)
Oil ring : 0.20 - 0.70mm (0.0079 - 0.0275in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)
Piston Pins
1. Measure the diameter of the piston pin.
Piston pin diameter
21.997 - 22.000mm (0.8660 - 0.8661in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.003 - 0.010mm (0.00011 - 0.00039in.)
Oil Pressure Switch
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) is applied through the oil hole, the switch is operaing properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
Reassembly
NOTE:
- Thoroughly clean all parts to assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.
(1) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
(2) Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.
CAUTION:
- Apply heat to the piston (70°C) and then install the piston pin.
- Take care that piston pin is not to be damaged during pressing process.
- When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner diameter as below.
Piston pin outer DIA. :
21.997mm ~ 22.000mm (0.8660 - 0.8661 in)
Connecting rod S/END inner DIA. :
22.005mm ~ 22.011mm (0.8663 - 0.8665 in)
- Take care that piston is not to be damaged during installing process. When replace the piston pin, check the gap as below.
Connecting rod bushing gap :
0.005mm ~ 0.014mm (0.00019 - 0.00055 in)
Piston pin BOSS gap :
0.003mm ~ 0.010mm (0.00012 - 0.00039 in) - Heat to 70°C
2. Install the piston rings.
(1) Install the oil ring spacer and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
4. Install the main bearings.
NOTE:
Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).
(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5. Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
6. Place the crankshaft(A) on the cylinder block.
7. Place the main bearing caps on cylinder block.
8. Install the main bearing cap bolts.
Tightening torque
14.7Nm (1.5kgf.m, 10.8lb-ft) + 29.4Nm (3.0kgf.m, 21.6lb-ft) + 120°
CAUTION:
Always use new main bearing cap bolts.
NOTE:
- The main bearing cap bolts are tightened in 2 progressive steps.
- If any of the bearing cap bolts in broken or deformed, replace it.
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts(A), in several passes, in the sequence shown.
(3) Retighten the bearing cap bolts by 120° in the numerical order shown. (Using the SST (09221-4A000))
(4) Check that the crankshaft turns smoothly.
9. Check crankshaft end play.
10. Install the piston and connecting rod assemblies.
NOTE:
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
(2) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
NOTE:
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
17.7 - 21.6Nm (1.8 - 2.2kgf.m, 13.0 - 15.9lb-ft) + 88 - 92°
NOTE:
Always use new connecting rod cap bolts.
11. Install the ladder frame (A).
Tightening torque :
27.5 - 31.4N.m (2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft)
NOTE:
- Before assembling ladder frame, the liquid sealant Loctite 5900H or THREEBOND 1217H should be applied ladder frame.
- The part must be assembled within 5 minutes after sealant was applied.
- Apply sealant to the inner threads of the bolt holes.
12. Install the rear oil seal.
(1) Apply engine oil to a new oil seal lip.
(2) Using SST (09231-H1100, 09214-3K100) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
13. Install the oil pump.
14. Install the water pump.
15. Install the knock sensor(A).
Tightening torque
16.7 - 25.5N.m (1.7 - 2.6kgf.m, 12.3 - 18.8lb-ft)
16. Install the tensioner assembly integrated bracket(A).
Tightening torque
39.2 - 44.1N.m (4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)
17. Install the power steering pump bracket and power steering pump.
18. Install the alternator.
19. Install the A/C compressor.
20. Install the cylinder head.
21. Install the timing chain.
22. Install the oil pan.
(1) Using a razor blade and gasket scraper, remove all the old gasket material from the gasket surfaces.
NOTE:
Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket LOCTITE5900H or THREEBOND 1217H equivalent (MS721-40).
NOTE:
- To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
23. Remove the engine stand.
24. A/T : Install the drive plate (A) with washer (B).
Tightening torque
117.7 - 127.5N.m (12 - 13kgf.m, 86.8 - 94.0lb-ft)
25. M/T : Install the flywheel.
Tightening torque
117.7 - 127.5N.m (12 - 13kgf.m, 86.8 - 94.0lb-ft)
NOTE:
- Always use new flywheel(drive plate) bolts.