Cylinder Block Disassembly and Inspection
PISTON AND CRANKSHAFT DISASSEMBLY
1. Remove engine.
2. Place engine on a work stand.
3. Drain coolant and oil.
4. Remove oil pan.
5. Remove the timing chain and cylinder head.
6. Remove pistons with connecting rods.
NOTE: When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70° C (140 to 158° F).
7. Remove rear oil seal retainer.
CAUTION:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When replacing piston rings, if there is no punchmark, install with either side up.
8. Before removing bearing beam and bearing cap, measure crankshaft end play. Refer to step No. 5 Crankshaft Assembly (this article) for the end play specifications. Loosen the bolts in numerical order using two or three passes.
PISTON ASSEMBLY
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70° C (140 to 158° F) and assemble piston, piston pin, connecting rod and new snap ring.
NOTE:
- Align the direction of piston and connecting rod.
- Numbers stamped on connecting rod and cap correspond to each cylinder.
- After assembly, make sure connecting rod swings smoothly.
3. Set piston rings as shown.
NOTE:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When replacing piston rings, these without punchmarks, present, piston rings can be mounted with either side up.
- Align piston rings so that end gaps are positioned as shown in the figure.
CRANKSHAFT ASSEMBLY
1. Set main bearings in their proper positions on cylinder block and main bearing beam. Confirm that correct main bearings are used.
2. A plastic zone tightening method is used for tightening the main bearing cap bolts. Measure d1 and d2 as shown in the figure.
NOTE: For the d2 measurement, select minimum diameter in the measuring area. If the difference between d1 and d2 exceeds the limit replace the bolts with new ones. The limit (d1 - d2) is 0.11 mm (0.0043 inch).
3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order.
NOTE: Lubricate threads and seat surfaces of the bolts with new engine oil. Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction.
4. Tightening all bolts in the order shown to 32 to 38 Nm (24 to 28 ft. lbs.). Then, turn all bolts another 90 to 95 degrees clockwise with angle wrench.
NOTE: After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
5. Measure crankshaft end play. The standard value is 0.10 to 0.25 mm (0.0039 to 0.0098 inch) and the limit is 0.30 mm (0.0118 inch). If beyond the limit, replace bearing with a new one.
6. Confirm that correct bearings are used and install the connecting rod bearings into the rods and caps.
7. Install pistons with connecting rods.
a. Install them into corresponding cylinders with tool. Be careful not to scratch cylinder wall with the connecting rod. Arrange so that front mark on piston head faces toward engine front.
b. A plastic zone tightening method is used for tightening connecting rod bolts and nuts. Check the old bolts for deformation before re-using them. Ensure that the connecting rod nut can be screwed smoothly as far as the bolt thread end. If this is not possible, use slide calipers to measure the outside diameter of the narrowest thread part of the bolt at 16 mm (0.63 inch) from the thread end. Replace the connecting rod bolt and nut, if out of specification. The standard value is 7.90 to 8.00 mm (0.3110 to 0.3150 inch) and the limit is 7.75 mm (0.3051 inch).
c. Lubricate threads and seat surfaces with new engine oil and install connecting rod caps. Tighten connecting rod bearing cap nuts to 19 to 21 Nm (14 to 15 ft. lbs.). Then, turn the nuts another 90 to 95 degrees clockwise with angle wrench.
8. Measure connecting rod side clearance. The standard 0.20 to 0.35 mm (0.0079 to 0.0138 inch). The limit is 0.40 mm (0.0157 inch). If beyond the limit, replace connecting rod and/or crankshaft.
9. Install rear oil seal retainer.