Part 1 of 2
Disassembly
CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Inspect the timing belt before removing the cylinder head.
- Turn the crankshaft pulley so that the No.1 piston is at top dead center.
- Engine removal is required for this procedure.
1. Remove the engine assembly from the vehicle.
2. Install the engine to engine stand for disassembly.
3. Remove the intake manifold and exhaust manifold.
4. Remove the timing chain.
5. Remove the water temperature control assembly.
6. Remove the cylinder head.
7. Remove the oil pump.
8. Remove the oil filter assembly.
9. Remove the drive plate (A) and adapter plate (B). (AT)
10. Remove the crankshaft adapter (A). (AT)
11. Remove the dual mass flywheel (DMF) (A). (MT)
12. Remove the water jacket separator (A).
13. Remove the oil cover (A) are the gasket (B).
14. Remove the knock sensor (A).
15. Remove the upper oil pan (A).
16. Remove the baffle plate (A).
17. Remove the rear oil seal case (A).
18. Remove the plug bolt (A) and the washer gasket (B).
19. Check the connecting rod end play.
20. Check the connecting rod cap oil clearance.
21. Remove the piston and 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.
22. Remove the crankshaft main bearing cap and check oil clearance.
23. Check the crankshaft end play.
24. Lift the crankshaft (A) out of engine, being careful not to damage journals.
NOTE:
Arrange the main bearings and thrust bearings in the correct order.
25. Remove the oil jets (A).
26. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove oil ring and coil spring by hand.
NOTE:
Arrange the piston rings in the correct order only.
27. Disconnect connecting rod from piston. Remove the snap ring at both ends of piston pin.
And push the piston pin to separate from piston and connecting rod.
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.)
A. If out-of-tolerance, install a new connecting rod.
B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod 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 :
27.5 - 31.4N.m (2.8 - 3.2kgf.m, 20.3 - 23.1 lb-ft) + 68 - 72°
NOTE:
Do not turn the crankshaft.
(7) Remove the bolts, connecting rod cap and bearinghalf.
(8) Measure the plastigage at its widest point.
Standard oil clearance :
0.044 - 0.062mm (0.0017 - 0.0024in.)
(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
Identification Of Connecting Rod
Crankshaft Pin Mark Location
Identification Of Crankshaft
Discrimination Of Crankshaft
Place Of Identification Mark (Connecting Rod Bearing)
Identification 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 bearing 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 :
49.0Nm(5.0 kgf.m, 36.2lb-ft) + 90° (No. 1 - 8)
19.6Nm(2.0 kgf.m, 14.5lb-ft)+ 120° (No. 9 - 16)
29.4 - 31.4Nm(3.0 - 3.2 kgf.m, 21.7 - 23.1lb-ft)
(No. 17 - 24)
NOTE:
Do not turn the crankshaft.
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance :
0.022 - 0.040mm (0.0009 - 0.0016in.)
(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.
Crankshaft bore mark location
Letters have been stamped on the block as a mark for the size of each of the 4 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
Discrimination Of Crankshaft
Place Of Identification Mark (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 :
0.10 - 0.28mm (0.0039 - 0.0110in.)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness :
2.41 - 2.45mm(0.0949 - 0.0964in.)
5. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
68.942 - 68.960mm (2.7142 - 2.7149in.)
Crank pin diameter :
54.954 - 54.972mm (2.1635 - 2.1642in.)
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
Cylinder Block
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of the 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.),
Less than 0.02mm(0.0008in.) / 150 x 150
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 :
[3.0L / 3.3L] 92.00 - 92.03mm (3.6220 - 3.6232in.)
[3.8L] 96.00 - 96.03mm (3.7795 - 3.7807in.)
6. Check the cylinder bore size code on the cylinder block.
Maximum limit size :96.28mm (3.7906in.)
7. Check the piston size code(A) and the front mark(B) on the piston top face.
8. Select the piston related to cylinder bore class.
Clearance :0.03 - 0.05mm(0.0012 - 0.0020in.)
Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.
NOTE:
The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D(Outer Diameter), calculate the new bore size.
New bore size = piston O.D + 0.03 to 0.05mm (0.0012 to 0.0020in) (clearance between piston and cylinder) - 0.01mm (0.0004in) (honing margin.)
4. Bore each of the cylinders to the calculated size.
CAUTION:
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard :0.03 - 0.05mm (0.0012 - 0.0020in)
NOTE:
When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.