Engine Block
Speciaf Tools ..........." 7-2
lllustlated Index ...................."..'.......... 7-3
Flywheel and Drive Plate
Repf acement """'.' 7-7
Connecting Rod and Crankshaft
End Play ..........."....7-8
Main Bearings
Clearance ............... 7-9
Selection ................7-10
Connecting Rod Bearings
clearance ....'.......... 7-11
Selection ................ 7-11
Pistons and Crankshaft
Removaf ................. 7 -12
Crankshaft
Inspection ."".........7-14
Pistons
Inspection ......"'.....7-15
fnstaffation .............7-23
Cylinder Block
lnspec'tion ..............7-16
Bore Honing ..........7-17
Piston Pins
Removal ...,...........'.7-17
lnstallation .............7-18
Inspection .'............7-19
Connecting Rods
Selection ................7-18
Piston Rings
End Gap ..........".."' 7'2O
Repfacement .........7-2O
Ring-to-Groove Clearance ...........'.'. 7 -21
Afignment .......""'.. 7'21
Crankshaft Oil Seal
fnstaffation .............7-22
Crankshaft
fnstaffation ..-.-..'.".' 7'23
Oil Pan
lnstallation .............7-26
Oil Seals
fnstaffation ....""""' 7-29
r-f
lllustrated Index
(cont'd)
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft(see page 7,11).identification markings
Lubricate all internal parts with engine oil duringreassembtv.
PISTON INSTALLATION DIRECTION:
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTON RINGSReplacement. page 7-20Measurement, pages 7 20 andj-21Alignment, page 7-21
PISTON PINRemoval, page 7,17Installation, page 7-18Inspection, page 7,19
CONNECTING RODEnd play, page 7-8Selection, page 7,18
CONNECTING RODBEARINGSClearance, page 7 11Selection, page 7-11
CONNECTING ROD BEARING CAPInstallation, page 7-23NOTE: lnstall caps so thebearing recess is on thesame side as the recessin the rod.
PISTONInspectron, page 7-15NOTE: Betore removing the piston, inspect thetop of the cylinder bore for carbon build-up orridge. Bemove ridge if necessary, page 7-13
ENGINE BLOCKCylinder bore inspection, page 7-16Warpage inspection, page 7,'16Cylinder bore honing, page 7,17
Inspect top of each cylinder borefor carbon build-up or ridgebefore removing piston.Remove ridge if necessary, page 7-13
CONNECTING ROD CAP NUT816A2 €ngin6:9 x 0.75 mm{0 N.m (4.1 kgt m, 30 tbf.ftlD16Y5, Dl6Y7. D16Y8 engines:8 x 0.75 mm3l N.m {3.2 kg{.m,23 tbt.fr)Apply engine oiltothe bolt threads.NOTE: After torquing each bearingcap, rotate crankshaft tocheck for binding.
7-6
Connecting Rod Bearings
Clearance
Remove the connecting rod cap and bearing half
Clean the crankshaft rod iournal and bearing half
with a clean shop towel.
Place plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the nuts.
Torque
Bl6A2 engine:
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5, D16Y7, D16Y8 enginss:
31 N'm (3.2 kgf.m, 23 lbf ftl
NOTE| Do not rotate the crankshaft during inspection.
Remove the rod cap and bearing half and measure
the widest part of the plastigage.
Connecting Rod Bearing-to.Journal Oil Glearance:
816A2 engine:
Standard lNewl: 0.032 - 0.050 mm
10.0013 - 0.0020 in)
Service Limit: 0.06 mm 10.002 inl
D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 0.020 - 0.038 mm
(0.0008 - 0.0015 in)
Service Limit 0.05 mm 10.002 inl
'1.
4.
lf the plastigage measures too wide or too narrow'
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
the color as shown in the right column), and
recheck the clearance.
CAUTION: Do not lile, shim, or scrape the bearings
or the caps to adiust clgarance.
lf 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: lf the Droper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
PLASTIGAGE STRIP
\
7.
7-11
Selection
CAUTION: lf the codes are indecipherable because of
an accumulation of dirt and dust, do not sclub them
with a wile brush or scraper. Clean them only with sol-
vent or detergent,
Connecting Rod Code Location
Numbers have been stamped on the side of each con
necting rod as a code for the size of the big end Use
them, and the letters stamped on the crankshaft (codes
for rod journal size), to choose the correct bearlngs
Half of number ls
stamped on bearingcap and the otherhalf is stamped onrod.
Bearing ldentilication
Color code is on theedge ofthe bearing.
lfA--;T] |
lle"'tt l;llcorlll ll
I lD;;ilril |l-l
Larger brg end bore
Smaller Smallerrod bearlngjournal (thicker)
---------------- Smallerbearing{thrcker)
RedPinkGreen
PinkGreen
GreenErownBlack
GreenBrownBlackBlue
1234
Connecting Rod Journal Code Locations (Lettels)
6. Remove the bolts and the bearing caps.
CAUTION: To prevenl warpago unscrow lhe bolts
in s€quence 1/3 turn at a tims, r€paat the soquence
until all bolts ar€ loo3ened.
MAIN BEARING CAP BOLTS LOOSENING SEOUENCE
Remove the rod caps/bearings and main capvbear-
ings. Keep all caps/bearing in order.
Lift the crankshaft out of the engine, being careful
not to damage journals.
7.
S:_]ILOJLOAO
CRANKSHAFT14.
7-13
qRemove the upper bearing halves from the connect-
ing rods and set them aside with their respective
caos.
Reinstall the main caps and bearings on the engine
in proper order,
lf you can feel ridge of metal or hard carbon around
the top of each cylinder, remove it with a ridge
reamer. Follow the reamer manufacturer's instruc-
I|ons.
CAUTION; lf the ridge is not removed, it may dam-
age tho pistons as they are pushod out.
RIOGE REAMER
10.
11.
12.Use the wooden handle of a hammer to drive the
pastons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
Mark each piston/connecting rod assembly with its
cylinder number to avoid mixup on reassembly.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.
PistonsGrankshaft
lnstallation
Before installing the pistons, apply a coat of
engine oil to the ring grooves and cylinder
bores.
lf the crankshaft is already installed:
. Set the crankshaft to BDC for each cylinder.
. Remove the connecting rod caps, and slip short
sections of rubber hose over the threaded ends
of the connecting rod bolts.
. lnstall 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.
o Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal align-
ment before pushing the piston into place
. Apply engine oil to the bolt threads. Install the
rod caps with bearings, and torque the nuts to:
815A2 engine:
40 N.m {,1.1 kgf.m, 30 lbf'ft|
D16Y5, D16Y7, D16Y8 engines:
31 N.m (3.2 kgf'm,23 lbf'ft)
lf the crankshaft is not installed:
. Remove the rod caps and bearings, install the ring
compressor, then position the piston in the cylin-
der, and tap it in using the wooden handle of a
hammer.
. Position all Distons at top dead center.
1.
2.
The arrcw must facethe taming belt sideof the engine.
CONNECTING ROOOIL HOLE lD16Y5, D16Y7, D16YB ongines)
NOTE: Maintain downward force on the ring com-
pressor to prevent the rings from expanding before
entering the cylinder bore.
RUBBER
,lll
lnstallation
Before installing the crankshaft, apply a coat of
engine oil to the main bearings and rod bearings.
Insert the bearing halves into the cylinder block and
connecting rods.
Hold the crankshaft so the rod journals for cylinders
No.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rod
journals into connecting rods No. 2 and No. 3, and
install the rod caps and nuts finger-tight.
1.
2.
3.
5.
Grooved sides faceoulward.Botate the crankshaft clockwise, seat journals into
connecting rods No, 1 and No.4, and install the rod
caps and nuts finger-tight.
NOTE: Install caps so the bearing recess is on the
same side as the recess in the rod.
Check rod bearing clearance with plastigage (see
page 7-11), then torque the capnuts. Apply engine
oil to the bolt threads.
Torque:
816A2 sngine:/l{, N.m {a.l kgf.m, 30 lbf'ftl
D16Y5, D16Y7, Dl6Y8 engines:
31 N.m (3.2 kgf.m, 23 lbf'ft|
NOTE: Reference numbers on connecting rod are
for big-end bore tolerance and do not indicate the
position of piston in the engine.
Line up the marks wheninstalling the connectrng rod
cap.
6. Install the thrust washers on the No. 4 journal. Oil(cont'd)
7-23
the thrust washer surfaces,