Repair Procedure
Engine Block/Crankshaft Area Replacement Components With Torque Specifications (1 Of 3)
| *: Learning | ■: SPL Tool |
Engine Block/Crankshaft Area Replacement Components (2 Of 3)
| *: Learning | ■: SPL Tool |
| *1: In the illustration, other parts are omitted because the component parts and the removal/installation procedure are the same. |
Engine Block/Crankshaft Area Replacement Components With Torque Specifications (3 Of 3)
| *: Learning | ■: SPL Tool |
- A.-
Key Information
Do the following before starting your work.
Remove:
Sub-Procedure
Installation
NOTICE:
Make sure the direction of the sensor connector (a) as shown.
Installation Directions
Position Direction Front Bank b Crankshaft Pulley Side Rear Bank Transmission Side - B.-
Key Information
Do the following before starting your work.
Remove:
Sub-Procedure
Installation
- Install a cooling control spacer (a) in the engine block whenever the engine block is replaced, and check for free play between the cooling control spacer and the engine block. If there is any free play, install a new cooling control spacer.
NOTICE:
- Make sure the cooling control spacer contacts the bottom of the water jacket (b).
- Make sure the cooling control spacer upper end portions and the clearance of the cylinder block end face.
Specifications
Standard Value c 0.2 mm (0.008 in) min. - C.-
Key Information
Do the following before starting your work.
Remove:
Sub-Procedure
Removal
NOTE: Be careful not to damage the crankshaft and the engine block end cover.
Figure 1
Figure 2
Installation
- Clean and dry the oil seal housing.
Lubricant Specifications (Figure 1)
Position Type a Engine Oil Installation Depth (Figure 2)
Standard Value b No Clearance - Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
- D.-
Key Information
Do the following before starting your work.
Remove:
Sub-Procedure
Installation
1. Remove all of the old gasket from the mating surfaces of each part and clean it.
Lubricant Specifications
Position Type Detail a Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718-0009) b 2.5 mm (0.098 in) Lubricant Specifications
Position Type The lip of the oil seal Engine Oil NOTICE:
- Install the component within 5 minutes of applying the liquid gasket.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the parts.
- E.-
Key Information
Do the following before starting your work.
Remove:
Sub-Procedure
Removal
NOTE: Be careful not to damage the engine oil pump.
Figure 1
Figure 2
Installation
- Clean and dry the oil seal housing.
Lubricant Specifications (Figure 1)
Position Type a Engine Oil Installation Depth (Figure 2)
Standard Value b No Clearance - Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
- F.-
Preconditions
Key Information
Do the following before starting your work.
Remove:
- Timing Belt Drive Pulley
- A/C Compressor/Engine Oil Pan Area Parts
- Oil Pan
- Oil Filter Base
Sub-Procedure
Installation
1. Remove all of the old gasket from the mating surfaces of each part and clean it.
Lubricant Specifications
Position Type Detail a Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718-0009) b 2.5 mm (0.098 in) Lubricant Specifications
Position Type The lip of the oil seal Engine Oil Lubricant Specifications
Object Type Specified Amount Pump Rotor Chamber Engine Oil 2 mL (0.07 fl oz, 0.07 Imp oz) NOTICE:
- Install the component within 5 minutes of applying the liquid gasket.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the parts.
- G.-
NOTICE:
Keep all removed parts in order, and install them of the original position when installing.
Sub-Procedure
Figure 1
Figure 2
Removal
- Refer to the figure 1.
NOTICE:
- If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (a). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it is pushed out. (Figure 2)
- Take care not to damage the cylinder with the connecting rod.
- Mark the cylinder number on the connecting rod and the connecting rod bearing cap to avoid mixing them up during reassembly.
Tool Details (Figure 2)
Name a Ridge Reamer (Commercially Available) Figure 3
Installation
1. Check the connecting rod bearing is securely in place.
Lubricant Specifications
Position Type - Piston
- Inside of Ring Compressor
- Cylinder Bore
Engine Oil 2. Position the piston/rod assembly with the arrow (b) facing the timing belt side of the engine block. (Figure 3)
Figure 4
3. Push down on the ring compressor (c) to prevent the rings from expanding before entering the cylinder bore. (Figure 4)
Tool Details (Figure 4)
Name c Ring Compressor (Commercially Available) 4. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.
5. Adjust the connecting rod bearing (if necessary).
Figure 5
6. Measure the diameter of each connecting rod bolt.
7. Calculate the difference in diameter between point (d) and point (e). (Figure 5)
Conditions (Figure 7)
Position d 35 mm (1.38 in) e 20 mm (0.79 in) Specifications (Figure 7)
Service Limit Outer diameter of the bolt (Difference in diameter) 0-0.1 mm (0-0.004 in) NOTE: If the difference in diameter is out of specification, replace the connecting rod bolt.
Figure 6
Figure 7
8. Set the crankshaft to bottom dead center (BDC) for the cylinder.
9. Install the connecting rod cap. Line up the mark (f) on the connecting rod and the connecting rod cap. (Figure 6)
Lubricant Specifications
Position Type - Threads
- Flange
Engine Oil Tightening Procedure (Figure 7)
Step Operation Standard Value 1 Hand Tighten The bolts until they sit on the connecting rod cap 2 Temporarily Tighten 20 Nm (15 lbfft) 3 Angle Tighten g 90° NOTICE:
Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 1 of the tightening procedure. Do not loosen it back to the specified angle.
10. Inspect the connecting rod and crankshaft end play - Refer to: Connecting Rod and Crankshaft End Play Inspection () or Piston, Ring, Pin, and Connecting Rod Inspection () . (if necessary)
- H.-
Key Information
Do the following before starting your work.
Remove:
- Engine Assembly
- Drive Plate
- Cylinder Head - Refer to: Cylinder Head Removal and Installation () or Engine Compression Inspection ()
- Timing Belt Drive Pulley
Sub-Procedure
NOTICE:
- Keep all removed parts in order, and install them of the original position when installing.
- Be careful not to damage the journals and the CKP pulse plate.
NOTE: The No. 1 journal is on the crankshaft pulley side.
Figure 1
Removal
- Loosen the bearing cap bolts and the bearing cap side bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. (Figure 1)
Figure 2
Installation
1. Adjust the main bearing (if necessary).
2. Install the crankshaft.
Lubricant Specifications
Position Type - Main Bearings
- Connecting Rod Bearings
Engine Oil 3. Install the thrust washer (a) as shown. (Figure 2)
Lubricant Specifications
Position Type Thrust Washer Surfaces Engine Oil Figure 3
Figure 4
4. Install the main bearings and the main bearing caps.
NOTE:Install the main bearing caps aligning the arrows (b) facing the timing belt side of the engine block. (Figure 3)
Lubricant Specifications
Position Type - Threads
- Flanges
Engine Oil Installation Directions
Position Direction c Crankshaft Pulley Side Specifications (Figure 4)
Position Type d 10 x 60 mm Position Type e 10 x 80 mm Figure 5
Figure 6
5. Tighten the bolts, in sequence. (Figure 5)
Tightening Procedure (Figure 5 and 6)
Step Operation Object Specification 1 Temporarily Tighten All Bolts 2 Tighten _
40 Nm (30 lbfft) 3 Angle Tighten _
f 47° 4 Tighten _
49 Nm (36 lbfft) - I.-
Sub-Procedure
NOTICE:
Keep all removed parts in order, and install them of the original position when installing.
Figure 1
Removal
- Refer to the Figure 1.
Tool Details (Figure 1)
Name a Ring Expander (Commercially Available) Figure 2
Installation
1. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools.
2. If necessary, inspect the piston ring end gap - Refer to: Block and Piston Inspection () or Piston, Ring, Pin, and Connecting Rod Inspection ()
.NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
Specifications (Figure 2)
Standard Value (New) b 1.2 mm (0.047 in) c 1.0 mm (0.039 in) d 2.0 mm (0.079 in) Figure 3
Figure 4
3. The manufacturing marks (e)/(f) must be facing upward. (Figure 3)
Specifications (Figure 3)
Marking Position Mark e 1R f 2R Specifications (Figure 4)
Standard Value (New) Top Ring g 3.1 mm (0.122 in) h 1.2 mm (0.047 in) Second Ring g 3.1 mm (0.122 in) h 1.0 mm (0.039 in) Lubricant Specifications
Position Type Piston Rings Engine Oil 4. Rotate the rings in their grooves to make sure they do not bind.
Figure 5
5. Position the ring end gaps as shown. (Figure 5)
Specifications (Figure 5)
Position Object i Oil Ring Gap k Second Ring Gap m Oil Ring Gap n Top Ring Gap and Spacer Ring Gap o Piston Pin Specifications (Figure 5)
Specifications p About 90° q About 45° After Installation
- If necessary, inspect the ring-to-groove clearance - Refer to: Block and Piston Inspection () or Piston, Ring, Pin, and Connecting Rod Inspection () .
- J.-
Sub-Procedure
NOTICE:
Keep all removed parts in order, and install them of the original position when installing.
Figure 1
Figure 2
Removal
1. Remove the snap rings.
Lubricant Specifications (Figure 1)
Position Type a Engine Oil - 1.Turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (b). (Figure 1)
NOTICE:
Take care not to damage the ring grooves.
- 2.Remove the snap rings from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear goggles or safety glasses to prevent eye injury. (Figure 2)
Figure 3
2. Remove the piston pin. (Figure 3)
- Heat the piston/rod assembly to about 158°F (70°C).
3. If necessary, do the following inspection.
- Piston Pin - Refer to: Block and Piston Inspection () or Piston, Ring, Pin, and Connecting Rod Inspection ()
- Piston Pin-to-Piston Clearance - Refer to: Block and Piston Inspection () or Piston, Ring, Pin, and Connecting Rod Inspection ()
- Piston Pin-to-Connecting Rod Clearance - Refer to: Block and Piston Inspection () or Piston, Ring, Pin, and Connecting Rod Inspection ()
- Piston Skirt Diameter - Refer to: Block and Piston Inspection () or Cylinder Bore Honing ()
- Piston-to-Cylinder Bore Clearance - Refer to: Block and Piston Inspection () or Cylinder Bore Honing ()
Figure 4
Installation
1. Install the snap ring. (only on one side)
2. Make sure the mark (c).
Specifications (Figure 3)
Marking Position Mark c 5J6 Figure 5
Figure 6
Figure 7
3. Install the piston pin.
Lubricant Specifications (Figure 5)
Position Type d Engine Oil e f - Heat the piston to about 158°F (70°C). (Figure 6)
- Align the arrow (g) with the groove (h) direction on the connecting rod as shown. (Figure 7)
NOTICE:
Pay attention to the direction for installing the connecting rod according to the marks.
4. Install the remaining snap ring.
- Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.
- K.-
Sub-Procedure
NOTICE:
Be careful not to damage the CKP pulse plate.
Installation
- Align the portion (a) on the CKP pulse plate and groove (b) on the crankshaft.
Lubricant Specifications
Position Type - Bolt Threads
- Bolt Flange
Engine Oil