1995 ACURA TL Service Repair Manual

Piston Pin sConnectin g Rod s
Remova lSelection
1. Assembl e th e specia l tool s a s shown .
PISTON BAS E HEA D07HAF-PL2010 2
PISTON PI N BAS E INSER T07GAF-PH6030 0
PISTON BAS E07973-657050 0
PISTON BAS E SPRIN G07973-657060 0
2. Assembl e an d adjus t th e lengt h o f th e pisto n pi n
drive r an d shaf t t o 51. 5 m m (2.0 3 in ) a s shown .
PISTON PI N DRIVE R HEA D07973-PE0032 0
PISTON PI N DRIVE RSHAFT07973-PE0031 0
PILOT COLLA R07GAF-PH7010 0
3.
NOTE : Us e hydrauli c press .When pressin g pi n i n o r out ,mak e sur e tha t th e recesse dportion o f th e pisto n align swith th e lip s o n th e collar .
Plac e th e pisto n o n th e pisto n bas e an d pres s th e
pi n ou t wit h th e specia l tool s a hydrauli c press . Eac
h ro d fall s int o on e o f fou r toleranc e range s (fro m O to
0.02 4 m m (0.000 9 in) , i n 0.00 6 m m (0.000 2 in ) incre -
ments ) dependin g o n th e siz e of its bi g en d bore . It' s
the n stampe d wit h a numbe r o r ba r (1 , 2 , 3 , o r 4/I , o r
ml ) indicatin g th e range .
You ma y fin d an y combinatio n o f 1 , 2 , 3 , o r 4/I ,
in an y engine .
Norma l Bor e Size : 48. 0 m m (1.8 9 in )
NOTE :
• Referenc e number s o r bar s ar e fo r bi g en d bor e
siz e an d d o no t indicat e th e positio n o f ro d i n th e
engine .
• Inspec t connectin g ro d fo r crack s an d hea t dam -
age.
CONNECTIN G RO D BOR EREFERENC E NUMBE R o r BA RHalf o f numbe r i s stampe d o nbearin g cap , th e othe r hal f o nconnectin g rod .
Inspec t bolt sand nut s fo rstres s cracks .
Embosse d mar k facin g u p
51. 5 mm(2.0 3 in)
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Piston Pin s
Inspectio n
1. Measur e th e diamete r o f th e pisto n pin .
Pisto n Pi n Diameter :
Standar d (New) : 21.99 4 - 22.00 0 m m
(0.865 9 - 0.866 1 in )
Oversize : 21.99 7 - 22.00 3 m m
(0.866 0 - 0.866 3 in )
NOTE : Al l replacemen t pisto n pin s ar e oversize .
2 . Zer o th e dia l indicato r t o th e pisto n pi n diameter . 3
. Measur e th e pisto n pin-to-pisto n clearance .
NOTE : Chec k th e pisto n fo r distortio n o r cracks .
I f th e pisto n pi n clearanc e i s greate r tha n 0.02 4 m m
(0.000 9 in) , remeasur e usin g a n oversize d pisto n
pin.
Pisto n Pin-to-Pisto n Clearance :
Standar d (New) : 0.01 2 - 0.02 4 m m
(0.000 5 - 0.000 9 in )
4 . Chec k th e differenc e betwee n th e pisto n pi n diame -
te r an d connectin g ro d smal l en d diameter .
Pisto n Pin-to-Connectin g Ro d Interference :
Standar d (New) : 0.01 3 - 0.03 2 m m
(0.0005-0.001 3 in )
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Piston Pin sPisto n Ring s
Installatio n
1. Us e a hydrauli c pres s fo r installation .
• Whe n pressin g th e pi n i n o r out , b e sur e t o posi -
tio n th e recesse d fla t o n th e pisto n agains t th e lug s
o n th e bas e attachment .
The arro w mus t fac e th etimin g bel t sid e o f th eengin e an d th e connectin grod oi l hole must fac e th eleft sid e o f th e engine .
End Ga p
PISTO N PI N DRIVE R HEA D07973-PE0032 0
Embossed mar kfacin g up .
Adjus t th e lengt h o fpisto n pi n drive r an d shaf t t o51.5m m (2.0 3 in )
PISTO N PI N DRIVE R SHAF T07973-PE0031 0
PISTON PI N
PILO T COLLA R07GAF-PH7010 0
1PISTON PI N BAS E INSER T07GAF-PH6030 0
PISTON BAS E HEA D07HAF-PL2010 2
1. Usin g a piston , pus h a ne w rin g int o th e cylinde r
bor e 15-2 0 m m (0. 6 - 0. 8 in ) fro m th e bottom .
2 . Measur e th e pisto n rin g end-ga p wit h a feele r gauge :
• I f th e ga p i s to o small , chec k t o se e i f yo u hav e
th e prope r ring s fo r you r engine .
• I f th e ga p i s to o large , rechec k th e cylinde r bor e
diamete r agains t th e wea r limit s o n pag e 7-12 .
I f th e bor e i s ove r th e servic e limit , th e cylinde r
bloc k mus t b e rebored .
Pisto n Rin g End-Gap :
Top Rin g
Standar d (New) : 0.2 0 - 0.3 0 m m
(0.008-0.01 2 in )
Servic e Limit : 0.5 0 m m (0.02 0 in )
Secon d Rin g
Standar d (New) : 0.3 5 - 0.5 0 m m
(0.014-0.02 0 in )
Servic e Limit : 0.6 5 m m (0.02 6 in )
Oil Rin g
Standar d (New) : 0.2 0 - 0.7 0 m m
(0.00 8 - 0.02 8 in )
Servic e Limit : 0.8 0 m m (0.03 1 in )
PISTO N RIN G15 — 2 0 m m(0.6-0. 8 in)
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Replacement
1. Usin g a rin g expander , remov e th e ol d pisto n rings .
2 . Clea n al l rin g groove s thoroughly .
NOTE:
• Us e a squared-of f broke n rin g o r rin g groov e
cleane r wit h blad e t o clea n pisto n grooves . Fil e
dow n blad e if necessary .
• To p an d 2n d rin g groove s ar e 1. 2 m m (0.0 5 in )
wid e an d oi l rin g groov e i s 2. 8 m m ( 0.11 in)
wide .
CAUTION : D o no t us e a wir e brus h t o clea n th e
ring grooves . D o no t us e th e cleanin g too l t o cu t
rin g groove s deeper .
NOTE : I f th e pisto n is t o b e separate d fro m th e con -
nectin g rod , d o no t instal l ne w ring s yet .
3 . Instal l ne w ring s i n th e prope r sequenc e an d posi -
tio n (se e pag e 7-18 ).
NOTE : D o no t reus e ol d pisto n rings .
RING EXPANDE R
(Commerciall y
available )
PISTO N RIN G
Ring-to-Groov e Clearanc e
After installin g a ne w se t o f rings , measur e ring-to -
groove clearance :
Top Rin g Clearanc e
Standar d (New) : 0.04 5 - 0.07 0 m m
(0.001 8 - 0.002 8 in )
Servic e Limit : 0.1 4 m m (0.00 6 in )
Secon d Rin g Clearanc e
Standard (New) : 0.03 0 - 0.05 5 m m
(0.0012-0.002 2 in )
Servic e Limit : 0.1 3 m m (0.00 5 in )
FEELE R GAUG E
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Piston Ring s
Crankshaft Oi l Sea l
Alignment Installation
1. Instal l th e ring s usin g th e rin g expande r show n o n
pag e 7-17 .
Identif y to p an d secon d ring s b y th e chamfe r o n th e
edge . Mak e sur e the y ar e i n thei r prope r groove s o n
piston .
NOTE : Th e manufacturin g mark s mus t b e facin g
upward .
TOP RIN G
SECON D RIN G
2. Rotat e th e ring s i n thei r groove s t o mak e sur e the y
do no t bind .
MAR K
TOP RIN G
OIL RIN G
MAR K
SPACE R
3. Positio n th e rin g en d gap s a s shown :
DO NO T positio n an y rin g ga pSECON D RIN G GA P a t pisto n thrus t surfaces .
Approx. 90 °
TOP RIN G GA P
DO NO T positio n an y rin g ga p
i n lin e wit h pisto n pi n hole .
OIL RIN GGAP
SPACE R GA P
OIL RIN GGAP
The sea l surfac e o n th e bloc k shoul d b e dry .
Appl y a ligh t coa t o f oi l t o th e crankshaf t an d
to th e li p o f seal .
1 . Driv e th e rea r crankshaf t oi l sea l int o th e rea r cove r
usin g th e specia l tools .
NOTE : Driv e th e rea r crankshaf t oi l sea l i n squarely .
DRIVER07749-001000 0
REAR COVE R
DRIVER ATTACHMEN T07948 - SB0010 1Install th e oi l sea l wit h th epar t numbe r sid efacin g out .
2. Confir m clearanc e i s equa l al l th e wa y aroun d wit h
a feele r gauge .
Clearance : 0. 5 - 0. 8 m m (0.0 2 - 0.0 3 in )
0.5—0. 8 m m
(0.02-0.0 3 in )
REA RCOVE R
REAR COVE RREAR CRANKSHAF T OI LSEA L
NOTE : Refe r t o page s 7-2 2 an d 8-1 5 fo r installatio n
o f th e fron t crankshaf t oi l seal .
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Pistons

Installation

Before installing the piston, apply a coat of

engine oil to the ring grooves and cylinder

bores.

1. If the crankshaft is already installed:

Remove the connecting rod caps and slip short

sections of rubber hose over the threaded ends

of the connecting rod bolts.

Install the ring compressor, check that the bear-

ing is securely in place, then position the piston

in the cylinder and tap it in using the wooden

handle of a hammer.

Stop tapping after the ring compressor pops

free, and check the connecting rod-to-crank jour-

nal alignment before pushing piston into place.

Install the rod caps with bearings, and torque the

nuts to 32 N-m (3.3 kgf-m, 24 Ibf-ft)

2. If the crankshaft is not installed:

Remove the rod caps and bearings, install the

ring compressor, then position the piston in the

cylinder and tap it in using the wooden handle of

a hammer.

Position all pistons at top dead center.

The arrow must face

the timing belt side

of the engine and the

connecting rod oil hole

must face the intake

manifold.

CONNECTING ROD

OIL HOLE

RUBBER HOSES

NOTE: Maintain downward force on the ring com-

pressor to prevent rings from expanding before

entering the cylinder bore.

Use the wooden handle

of a hammer to push, or

tap the piston into the

cylinder bore.
RING

COMPRESSOR

(Commercially

available)ProCarManuals.com

Crankshaft
Installation
Before installin g th e crankshaft , appl y a coa t
o f engin e oi l t o th e mai n bearing s an d ro d
bearings .
1. Inser t bearin g halve s i n th e cylinde r bloc k an d con -
nectin g rods .
2 . Instal l th e thrus t washer s i n th e No . 4 journal . Oi l
th e thrus t washe r surfaces .
3 . Lowe r th e crankshaf t int o th e cylinde r block , seatin g
th e ro d journal s int o connectin g rod s No . 1 , No . 2
an d No . 5 . Instal l th e ro d cap s an d nut s finger-tight .
4 . Rotat e th e crankshaf t clockwise , sea t journal s int o
connectin g rod s No . 3 an d No . 4 , an d instal l th e ro d
cap s an d nut s finge r tight .
NOTE : Instal l cap s s o th e bearin g reces s i s o n th e
sam e sid e a s th e reces s in th e rod .
5 . Chec k ro d bearin g clearanc e wit h plastigag e (se e
pag e 7-8 ), the n torqu e th e capnuts .
3 2 N- m (3. 3 kgf-m , 2 4 Ibf-ft )
NOTE :
• Referenc e number s o n connectin g ro d ar e fo r
big-en d bor e toleranc e an d d o no t indicat e th e
positio n o f pisto n i n th e engine .
• Coa t th e bol t thread s wit h engin e oil .
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Crankshaft
Installation (cont'd )
6. Instal l th e mai n bearin g caps .
Chec k clearanc e wit h plastigag e (se e pag e 7-7 ), the n
tighte n th e bearin g ca p bolt s i n tw o steps .
I n th e firs t step , torqu e al l bolt s i n sequenc e t o abou t
2 9 N- m (3. 0 kgf-m , 2 2 Ibf-ft) ; i n th e fina l step , torqu e in
sam e sequenc e to 7 4 N- m (7. 5 kgf-m , 5 4 Ibf-ft) .
NOTE : Coa t th e bol t thread s wit h engin e oil .
7.
CAUTION : Wheneve r an y crankshaf t bearin g o r
connectin g ro d bearin g is replaced , i t i s necessar y
afte r reassembl y t o ru n th e engin e a t idlin g spee d
unti l i t reache s norma l operatin g temperature , the n
continu e to ru n it fo r approximatel y 1 5 minutes .
Appl y liqui d gaske t t o th e cylinde r bloc k matin g sur -
fac e o f th e rea r cover , the n instal l i t o n th e cylinde r
block .
Apply liqui d gaske talong th e broke n line .REA R COVE R
NOTE:
• Us e liqui d gasket , Par t No . 0871 8-000 1 o r 0871 8
- 0003 .
• Chec k tha t th e matin g surface s ar e clea n an d dr y
befor e applyin g liqui d gasket .
8.
• Appl y liqui d gaske t evenly , bein g carefu l t o cove r
al l th e matin g surface .
• T o preven t oi l leakage , appl y liqui d gaske t t o th e
inne r thread s o f th e bol t holes .
• D o no t appl y liqui d gaske t t o O-rin g grooves .
• D o no t instal l th e part s i f fiv e minute s o r mor e
hav e elapse d sinc e applyin g liqui d gasket .
Instea d reappl y liqui d gaske t afte r removin g ol d
residue .
• Afte r assembly , wai t a t leas t 3 0 minute s befor e
filling th e engin e wit h oil .
• Appl y a ligh t coa t o f oi l t o th e crankshaf t an d t o
th e li p o f seal .
• Us e a ne w O-rin g an d appl y oi l whe n installin g it .
DOWE L PI N
REA R COVE R
Apply liqui d gaske t t o th e cylinde r bloc k matin g sur -
fac e o f th e oi l pump , the n instal l i t o n th e cylinde r
block .
NOTE : D o no t appl y liqui d gaske t t o O-rin g grooves .
Apply liqui d gaske t
alon g th e broke n line .
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