CYLINDER BLOCK
EM-81
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
• The difference (A) between main bearing upper (1) and
main bearing lower (3) should be 0.85 mm (0.033 in) or
less when installing.
• Ensure the oil holes on cylinder block and oil holes (A) on
the main bearings (1) are aligned.
6. Install signal plate to crankshaft if removed.
7. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crank-
shaft rear surface.
8. Apply new engine oil to threads and seat surfaces of bolts.
9. Position crankshaft (2) and signal plate (1) using a dowel pin
(service part), and tighten bolts in numerical order as shown.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
10. Tighten bolts in numerical order as shown.
11. Remove dowel pin. (service parts)
CAUTION:
Be sure to remove dowel pin.
12. Install crankshaft to cylinder block.
• While turning crankshaft by hand, make sure that it turns smoothly.
13. Install main bearing caps referring to the journal No. stamp (A)
and front mark (B) as shown.
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
14. Apply new engine oil to threads and seat surfaces of bolts.
2 : Cylinder block
4 : Main bearing cap
PBIC3237J
PBIC3236J
A : Dowel pin hole
PBIC3238J
: Engine front
PBIC3239J
EM-82
< SERVICE INFORMATION >
CYLINDER BLOCK
15. Tighten main bearing cap bolts in two steps.
NOTE:
Tighten main bearing cap bolts in numerical order as shown:
• After installing bolts, make sure that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-93, "
Inspection After Disassembly".
16. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
17. Assemble piston to connecting rod.
• Using a suitable tool, heat the piston until the piston pin can be pushed in by hand without excess force
[approximately 60° to 70 °C (140° to 158 °F)]. From the front to the rear, insert piston pin into piston and
connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (C) on connecting rod
are positioned as shown.
18. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, make sure that connecting rod moves
smoothly.
19. Using a suitable tool, install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
: Engine front
Step 1 : 34.3 N·m (3.5 kg-m, 25 ft-lb)
Step2 60° clockwise
PBIC3235J
Tool number : KV10112100 (BT-8653-A)
PBIC3240J
D : Big end diameter grade
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
PBIC3587J
CYLINDER BLOCK
EM-83
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
• Position each ring with the gap as shown referring to the pis-
ton front mark.
CAUTION:
Never contact the rail end gap under the oil ring with the
oil drain cast groove of piston.
• Install second ring with the stamped surface facing upward.
20. Install connecting rod bearing upper (2) and lower (3) to con-
necting rod (1) and connecting rod cap (4).
• Install the connecting rod in the dimension shown.
• Make sure that connecting rod bearing oil hole (A) is com-
pletely in the inside of connecting rod oil hole chamfered area
(B).
• When installing connecting rod bearings, apply new engine oil
to the bearing surface (inside). Do not apply new engine oil to
the back surface, but thoroughly clean it.
NOTE:
• There is no positioning tab.
• Install the connecting rod bearings in the center of connect-
ing rod and connecting rod bearing cap as shown. For ser-
vice operation, the center position can be checked, visually.
21. Install piston and connecting rod assembly to crankshaft.
• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number (C) on
connecting rod to install.
• Install so that front mark (A) on the piston head faces the front
of engine.
A : Oil ring upper or lower rail gap
B : Front mark
C : Second ring and oil ring spacer gap
D : Top ring gap
E : Stamped mark
PBIC3588J
C : Oil hole (connecting rod)
D : Arrow view
: Engine front
PBIC4541E
B : Oil hole
D : Big end diameter grade
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
PBIC3587J
EM-84
< SERVICE INFORMATION >
CYLINDER BLOCK
• Using a piston ring compressor [SST: EM03470000 (J-8037)]
(A) or suitable tool, install piston with the front mark on the pis-
ton head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
22. Install connecting rod cap.
• Match the stamped cylinder number marks (C) on connecting
rod with those on connecting rod cap to install.
23. Tighten connecting rod bolt with the following procedure:
CAUTION:
• Make sure that there is no gap in the thrust surface (A) of
the joint between connecting rod (1) and connecting rod
bearing cap (2) and that these parts are in the correct
position. And then, tighten the connecting rod bolts.
• If the connecting rod bolts are reused, measure the outer
diameter. Refer to EM-93, "
Inspection After Disassembly".
24. Apply new engine oil to the threads and seats of connecting rod
bolts.
25. Tighten bolts in three steps
• After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-93, "
Inspection After Disassembly".
26. Install oil pan (upper). Refer to EM-24
.
NOTE:
Install the rear oil seal after installing the oil pan (upper).
27. Install rear oil seal. Refer to EM-24
.
28. Install flywheel (M/T models) or drive plate (1) (A/T or CVT mod-
els).
• Secure crankshaft using Tool. (A), and tighten bolts crosswise
over several times.
NOTE:
A/T model shown CVT and M/T similar.
PBIC3244J
A : Front mark (piston)
B : Oil hole
D : Big end diameter grade
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
PBIC3587J
Step 1 : 27.4 N·m (2.8 kg-m, 20 ft-lb)
Step 2 : 0 N·m (0 kg-m, 0 ft-lb)
Step 3 : 19.6 N·m (2.0 kg-m, 14 ft-lb)
Tool number : KV11105210 (J-44716)PBIC3510J
PBIC3998E
CYLINDER BLOCK
EM-85
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
• Install pilot converter (1), drive plate (2) and reinforcement
plate (3) as shown (A/T or CVT models).
• Using a suitable tool of 33 mm. (1.30 in) in diameter, press-fit
pilot converter into the end of crankshaft until it stops (A/T or
CVT models).
NOTE:
M/T models have no pilot converter and reinforcement plate.
29. Install knock sensor (1) with connector facing toward the rear of
engine.
CAUTION:
• Never tighten bolts while holding the connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
• Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
• Make sure that knock sensor does not interfere with other parts.
30. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.
CAUTION:
• Avoid impacts such as a dropping.
• Keep it away from metal particles.
• Never place sensor in a location where it is exposed to magnetism.
31. Install oil filter (for intake valve timing control) (1) in the direction
shown.
• Make sure that the oil filter does not protrude from the upper
surface of cylinder block (2) after installation.
32. Assemble in the reverse order of disassembly.
How to Select Piston and BearingINFOID:0000000001702511
DESCRIPTION
A : Crankshaft rear end
B: R
PBIC4075E
A : Cylinder block left side
: Engine front
PBIC3246J
PBIC3260J
CYLINDER BLOCK
EM-95
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (A).
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP
• Make sure that cylinder bore inner diameter is within specification. Follow the "Cylinder Bore Inner Diameter"
procedure.
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversized piston and piston rings.
CONNECTING ROD BEND AND TORSION
Standard:
Top ring : 0.04 - 0.08 mm (0.002 - 0.003 in)
2nd ring : 0.03 - 0.07 mm (0.001 - 0.003 in)
Oil ring : 0.015 - 0.185 mm (0.001 - 0.007 in)
Limit:
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.0039 in)
PBIC3280J
Standard:
Top ring : 0.20 - 0.30 mm (0.008 - 0.012 in)
2nd ring : 0.50 - 0.65 mm (0.020 - 0.026 in)
Oil ring
(rail ring) : 0.15 - 0.45 mm (0.006 - 0.018 in)
Limit:
Top ring : 0.51 mm (0.020 in)
2nd ring : 0.83 mm (0.033 in)
Oil ring
(rail ring): 0.78 mm (0.031 in)
PBIC3267J
CYLINDER BLOCK
EM-97
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
Measure the outer diameter of piston pin with a micrometer (A).
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, follow the "PISTON TO PISTON PIN OIL CLEARANCE" proce-
dure.
• If replacing connecting rod assembly, follow the "Connecting Rod Bushing Oil Clearance" procedure to
select connecting rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler
gauge (B).
• If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-77, "
Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore gauge.
• Measure the position shown [5 mm (0.20 in)] backward from main
bearing housing front side in the 2 directions as shown. The
smaller one is the measured value.
• If out of the standard, replace cylinder block and main bearing
caps assembly.
NOTE:Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)
PBIC3266J
Standard : 0.005 - 0.023 mm (0.0002 - 0.0009 in)
Limit : 0.03 mm (0.0012 in)
Limit: 0.1 mm (0.004 in)
PBIC3250J
1 : Cylinder block
2 : Main bearing cap
: Engine front
Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in)
PBIC4005E
EM-100
< SERVICE INFORMATION >
CYLINDER BLOCK
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod bolts to the
specified torque. Refer to EM-77, "
Disassembly and Assembly"
for tightening procedure.
• Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-85, "
How
to Select Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-77, "
Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-77, "
Disassembly and Assembly" for the tightening
procedure.
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
A : Example
B : Inner diameter measuring direction
Standard : 0.037 - 0.047 mm (0.0015 - 0.0019 in)
Limit : 0.07 mm (0.0028 in)
PBIC3275J
PBIC3276J
A : Example
B : Inner diameter measuring direction
Standard:
No. 1, 4 and 5 journals
: 0.024 - 0.034 mm (0.0009 - 0.0013 in)
No. 2 and 3 journals
: 0.012 - 0.022 mm (0.0005 - 0.0009 in)
Limit : 0.065 mm (0.0026 in)
PBIC3277J