1. |
M/T : remove
flywheel. |
2. |
A/T : remove drive
plate. |
3. |
Install engine to engine stand for
disassembly. |
6. |
Remove oil level gauge
assembly(A).

|
7. |
Remove knock sensor(A).

|
8. |
Remove oil pressure sensor(A).

|
10. |
Remove oil pan(A).

•
|
Insert the SST between the oil pan
and the ladder frame by tapping it with a plastic hammer
in the direction of
arrow. |
•
|
After tapping the SST with a
plastic hammer along the direction of arrow around more than 2/3 edge
of the oil pan, remove it from the ladder
frame. |
•
|
Do not turn over the SST abruptly
without tapping. It is result in damage of the
SST. | | |
11. |
Remove oil screen.
Remove the 2bolts(C), oil screen(A) and
gasket(B).

|
12. |
Check the connecting rod end
play. |
13. |
Remove the connecting rod caps and check oil
clearance. |
14. |
Remove piston and connecting rod
assemblies.
(1) |
Using a ridge reamer, remove all the
carbon from the top of the
cylinder. |
(2) |
Push the piston, connecting rod assembly
and upper bearing through the top of the cylinder
block.
• |
Keep the bearings,
connecting rod and cap
together. |
• |
Arrange the piston and
connecting rod assemblies in the correct
order. | | | |
16. |
Remove rear oil seal case.
Remove the 5 bolts(B) and rear oil seal
case(A).

|
17. |
Remove crankshaft bearing cap and check oil
clearance. |
18. |
Check the crankshaft end
play. |
19. |
Lift the crankshaft(A) out of the engine,
being careful not to damage journals.
Arrange the main bearings and thrust
bearings in the correct
order. |

|
20. |
Check fit between piston and piston
pin.
Try to move the piston back and forth on the
piston pin. If any movement is felt, replace the piston and pin as a
set. |
21. |
Remove piston rings.
(1) |
Using a piston ring expender, remove the
2 compression rings. |
(2) |
Remove 2 side rails and the spacer by
hand.
Arrange the piston rings in the
correct order
only. | | |
22. |
Disconnect connecting rod from
piston. |
CONNECTING ROD AND CRANKSHAFT
1. |
Check the connecting rod end
play.
Using a feeler gauge, measure the end play
while moving the connecting rod back and forth.
Standard end play : 0.1~ 0.25mm(0.004 ~
0.010in.)
Maximum end play :
0.4mm(0.016in.)
|

A. |
If out-of-tolerance, install a new
connecting rod. |
B. |
If still out-of-tolerance, replace the
crankshaft. | |
2. |
Check the connecting road bearing oil
clearance.
(1) |
Check the matchmarks on the connecting
rod and cap are aligned to ensure correct
reassembly. |
(2) |
Remove 2 connecting rod cap
nuts. |
(3) |
Remove the connecting rod cap and
bearing half. |
(4) |
Clean the crank pin and
bearing. |
(5) |
Place plastigage across the crank
pin. |
(6) |
Reinstall the bearing half and cap, and
torque the nuts.
Tightening torque
49.0 ~ 52.0Nm (5.0 ~ 5.3kgf.m,
36.2 ~ 38.3lb-ft)
|
Do not turn the
crankshaft. | |
(7) |
Remove 2 nuts, connecting rod cap and
bearing half. |
(8) |
Measure the plastigage at its widest
point.
Standard
oil clearance
0.024 ~ 0.042mm(0.0009 ~
0.0017in.)
|

|
(9) |
If the plastigage measures too wide or
too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the
color as shown in the next column), and recheck the
clearance.
Do not file, shim, or scrape the
bearings or the caps to adjust
clearance. | |
(10) |
If 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.
If the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start
over. |
If the marks are indecipherable
because of an accumulation of dirt and dust, do not
scrub them with a wire brush or scraper. Clean them only
with solvent or
detergent. |
Connecting rod
mark location

Discrimination of connecting rod
CLASS
|
MARK
|
INSIDE
DIAMETER
|
a
|
A
|
48.00 ~ 48.006mm (1.8896 ~ 1.8899in.)
|
b
|
B
|
48.006 ~ 48.012mm (1.8899 ~ 1.8902in.)
|
c
|
C
|
48.012 ~ 48.018mm (1.8902 ~
1.8904in.)
|
Crankshaft pin
mark location


Discrimination of crankshaft
CLSASS
|
MARK
|
OUTSIDE DIAMETER OF
PIN
|
I
|
1
|
44.960 ~ 44.966mm (1.7700 ~ 1.7703in.)
|
II
|
2
|
44.952 ~ 44.960mm (1.7698 ~ 1.7700in.)
|
III
|
3
|
44.946 ~ 44.952mm (1.7695 ~
1.7698in.)
|
Place of
identification mark (Connecting rod bearing)

Discrimination of connecting rod bearing
CLASS
|
MARK
|
THICKNESS OF
BEARING
|
AA
|
BLUE
|
1.514 ~ 1.517mm (0.0596 ~ 0.0597in.)
|
A
|
BLACK
|
1.511 ~ 1.514mm (0.0595 ~ 0.0596in.)
|
B
|
NONE
|
1.508 ~ 1.511mm (0.0594 ~ 0.0595in.)
|
C
|
GREEN
|
1.505 ~ 1.508mm (0.0593 ~ 0.0594in.)
|
D
|
YELLOW
|
1.502 ~ 1.505mm (0.0591 ~
0.0593in)
|
|
(11) |
Selection
CRANKSHAFT
INDENTIFICATION MARK
|
CONNECTING ROD
IDENTIFICATION MARK
|
ASSEMBING
CLASSIFICATION OF BEARING
|
I (YELLOW)
|
a (WHITE)
|
D (YELLOW)
|
b (NONE)
|
C (GREEN)
|
c (YELLOW)
|
B (NONE)
|
II (NONE)
|
a (WHITE)
|
C (GREEN)
|
b (NONE)
|
B (NONE)
|
c (YELLOW)
|
A (BLACK)
|
III (WHITE)
|
a (WHITE)
|
B (NONE)
|
b (NONE)
|
A (BLACK)
|
c (YELLOW)
|
AA
(BLUE)
|
| |
3. |
Check the crankshaft bearing oil
clearance.
(1) |
To check main bearing-to-journal oil
clearance, remove the main caps and bearing
halves. |
(2) |
Clean each main journal and bearing half
with a clean shop tower. |
(3) |
Place one strip of plastigage across
each main journal. |
(4) |
Reinstall the bearings and caps, then
torque the bolts.
Tightening torque
29.4Nm (3.0kgf.m, 21.7lb-ft) + 60°
~ 65°
|
Do not turn the
crankshaft. | |
(5) |
Remove the cap and bearing again, and
measure the widest part of the plastigage.
Standard oil
clearance
0.028 ~ 0.046mm (0.0011 ~
0.0018in.)
|

|
(6) |
If the plastigage measures too wide or
too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the
color as shown in the next column), and recheck the
clearance.
Do not file, shim, or scrape the
bearings or the caps to adjust
clearance. | |
(7) |
If 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.
If the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start
over. |
If the marks are indecipherable
because of an accumulation of dirt and dust, do not
scrub them with a wire brush or scraper. Clean them only
with solvent or
detergent. | | |
Connecting rods
1. |
When reinstalling, make sure that cylinder
numbers put on the connecting rod and cap at disassembly match. When
a new connecting rod is installed, make sure that the notches for
holding the bearing in place are on the same
side. |
2. |
Replace the connecting rod if it is damaged on
the thrust faces at either end. Also if step wear or a severely
rough surface of the inside diameter of the small end is apparent,
the rod must be replaced as well. |
3. |
Using a connecting rod aligning tool, check
the rod for bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting rod that
has been severely bent or distorted should be replaced.
Allowable bend of connecting rod
:
0.05mm / 100mm (0.0020 in./3.94 in.) or
less
Allowable twist of connecting rod
:
0.1mm / 100mm (0.0039 in./3.94 in.) or
less
|
Crankshaft bore mark
location
Letters have been stamped on the end of the
block as a mark for the size of each of the 5 main journal
bores.
Use them, and the numbers or bar stamped on
the crank (marks for main journal size), to choose the correct
bearings.

Discrimination of cylinder block
CALSS
|
MARK
|
INSIDE
DIAMETER
|
a
|
A
|
61.000
~ 61.006mm (2.4015 ~
2.4018in.)
|
b
|
B
|
61.006
~ 61.012mm (2.4018 ~
2.4020in.)
|
c
|
C
|
61.012
~ 61.018mm (2.4020 ~
2.4023in.)
|
Crankshaft journal
mark location


Discrimination of crankshaft
CLASS
|
MARK
|
OUTSIDE DIAMETER OF
JOURNAL
|
I
|
YELLOW
|
56.956
~ 56.962mm (2.2423 ~
2.2426in.)
|
II
|
NONE
|
56.948
~ 56.956mm (2.2420 ~
2.2423in.)
|
III
|
WHITE
|
56.942
~ 56.948mm (2.2418 ~
2.2420in.)
|
Place of
identification mark (Crankshaft bearing)

Discrimination of crankshaft bearing
CLASS
|
MARK
|
THICKNESS OF
BEARING
|
AA
|
BLUE
|
2.014
~ 2.017mm (0.0793 ~
0.0794in.)
|
A
|
BLACK
|
2.011
~ 2.014mm (0.0791 ~
0.0793in.)
|
B
|
NONE
|
2.008
~ 2.011mm (0.0790 ~
0.0791in.)
|
C
|
GREEN
|
2.005
~ 2.008mm (0.0789 ~
0.790in.)
|
D
|
YELLOW
|
2.002
~ 2.005mm (0.0788 ~
0.0789in.)
|
Selection
CRANKSHAFT IDENTIFICATION
MARK
|
CRANKSHAFT BORE
IDENTIFICATION MARK
|
ASSEMBLING CLASSIFICATION
OF BEARING
|
I (YELLOW)
|
a
(A)
|
D
(YELLOW)
|
b
(B)
|
C
(GREEN)
|
c
(C)
|
B
(NONE)
|
II (NONE)
|
a
(A)
|
C
(GREEN)
|
b
(B)
|
B
(NONE)
|
c
(C)
|
A
(BLACK)
|
III (WHITE)
|
a
(A)
|
B
(NONE)
|
b
(B)
|
A
(BLACK)
|
c
(C)
|
AA
(BLUE)
|
|
4. |
Check crankshaft end play.
Using a dial indicator, measure the thrust
clearance while prying the crankshaft back and forth with a
screwdriver.
Standard end
play
0.06 ~ 0.26mm (0.0023 ~
0.010in.)
Limit : 0.30mm
(0.0118in.)
|

If the end play is greater than maximum,
replace the thrust bearings as a set.
Thrust bearing
thickness
2.44 ~ 2.47mm(0.096 ~
0.097in.)
| |
5. |
Inspect main journals and crank
pins
Using a micrometer, measure the diameter of
each main journal and crank pin.
Main journal diameter : 57mm
(2.165in.)
Crank pin diameter : 45mm
(1.77in.)
|

|
CYLINDER BLOCK
1. |
Remove gasket material.
Using a gasket scraper, remove all the gasket
material from the top surface of the cylinder
block. |
2. |
Clean cylinder block
Using a soft brush and solvent, thoroughly
clean the cylinder block. |
3. |
Inspect top surface of cylinder block for
flatness.
Using a precision straight edge and feeler
gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of
cylinder block gasket surface
Standard : Less than 0.03mm(0.0012
in.)
Limit : 0.05 mm (0.0020
in.)
|

|
4. |
Inspect cylinder bore diameter
Visually check the cylinder for vertical
scratchs.
If deep scratches are present, replace the
cylinder block. |
5. |
Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the
cylinder bore diameter at position in the thrust and axial
directions.
Standard
diameter
82.00 ~ 82.03mm (3.2283 ~
3.2295in.)
|

|
6. |
Check the cylinder bore size code on the
cylinder block bottom face.

Class
|
Cylinder bore inner
diameter
|
Size code
|
A
|
82.00
~ 82.01mm (3.228~
3.2287in.)
|
A
|
B
|
82.01
~ 82.02mm (3.2287~
3.2291in.)
|
B
|
C
|
82.02
~ 82.03mm (3.2291~
3.2295in.)
|
C
|
|
7. |
Check the piston size code on the piston top
face.

Stamp the grade mark of basic diameter
with rubber stamp. |
Class
|
Piston outer
diameter
|
Size code
|
A
|
81.97
~ 81.98mm (3.2271 ~
3.2275in.)
|
A
|
B
|
81.98
~ 81.99mm (3.2275 ~
3.2279in.)
|
None
|
C
|
81.99
~ 82.00mm (3.2279 ~
3.2283in.)
|
C
|
|
8. |
Select the piston related to cylinder bore
class.
Clearance : 0.02 ~ 0.04mm (0.00078 ~
0.00157in.)
| |
Boring cylinder
1. |
Oversize pistons should be selected according
to the largest bore cylinder.
Identification
Mark
|
Size
|
0.25
|
0.25mm
(0.010in.)
|
0.50
|
0.50mm
(0.020in.)
|
The size of piston is stamped on top of
the
piston. | |
2. |
Measure the outside diameter of the piston to
be used. |
3. |
According to the measured O.D., calculate the
new bore size.
New bore size = Piston O.D + 0.02 to
0.04mm
(0.0008 to 0.0016in.) (clearance between
piston and
cylinder) - 0.01mm (0.0004in.) (honing
margin.)
| |
4. |
Bore each of the cylinders to the calculated
size.
To prevent distortion that may result
from temperature rise during honing, bore the cylinder holes
in the firing
order. | |
5. |
Hone the cylinders, finishing them to the
proper dimension (piston outside diameter + gap with
cylinder). |
6. |
Check the clearance between the piston and
cylinder.
Standard : 0.02 ~ 0.04mm (0.0008 ~
0.0016in.)
|
When boring the cylinders, finish all of
the cylinders to the same oversize. Do not bore only one
cylinder to the
oversize. | |
PISTON AND RINGS
1. |
Clean piston
(1) |
Using a gasket scraper, remove the
carbon from the piston top. |
(2) |
Using a groove cleaning tool or broken
ring, clean the piston ring
grooves. |
(3) |
Using solvent and a brush, thoroughly
clean the piston.
| |
2. |
The standard measurement of the piston outside
diameter is taken 47 mm (1.85 in.) from the top land of the
piston.
Standard
diameter
81.97 ~ 82.00mm (3.2272 ~
3.2283in.)
|

|
3. |
Calculate the difference between the cylinder
bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.02 ~ 0.04mm(0.0008 ~
0.0016in.)
| |
4. |
Inspect the piston ring side
clearance.
Using a feeler gauge, measure the clearance
between new piston ring and the wall of the ring
groove.
Piston ring
side clearance
No. 1 : 0.04 ~ 0.08mm (0.0016 ~
0.0031in.)
No. 2 : 0.03 ~ 0.07mm (0.0012 ~
0.0028in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm
(0.004in.)
|

If the clearance is greater than maximum,
replace the piston. |
5. |
Inspect piston ring end gap.
To measure the piston ring end gap, insert a
piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a
piston. Measure the gap with a feeler gauge. If the gap exceeds the
service limit, replace the piston ring. If the gap is too large,
recheck the cylinder bore diameter against the wear limits. If the
bore is over the service limit, the cylinder block must be
rebored.
Piston ring
end gap
Standard
No.1 : 0.23 ~ 0.38mm (0.0091 ~
0.0150in.)
No.2 : 0.45 ~ 0.60mm (0.0177 ~
0.0236in.)
Limit
No. 1, 2, oil ring : 1.0mm
(0.039in.)
|

|
PISTON PINS
1. |
Measure the diameter of the piston
pin.
Piston pin
diameter
20.001 ~ 20.006mm (0.7874 ~
0.7876in.)
|

|
2. |
Measure the piston pin-to-piston
clearance.
Piston
pin-to-piston clearance
0.01 ~ 0.02mm (0.0004 ~
0.0008in.)
| |
3. |
Check the difference between the piston pin
diameter and the connecting rod small end diameter.
Piston
pin-to-connecting rod interference
0.016 ~ 0.032mm (0.00063 ~
0.00126in.)
| |
OIP PRESSURE SWITCh
1. |
Check the continuity between the terminal and
the body with an ohmmeter.
If there is no continuity, replace the oil
pressure switch.

|
2. |
Check the continuity between the terminal and
the body when the fine wire is pushed. If there is continuity even
when the fine wire is pushed, replace the
switch. |
3. |
If there is no continuity when a 50kpa (7psi)
vacuum is applied throgh the oil hole, the switch is operaing
properly.
Check for air leakage. If air leaks, the
diaphragm is broken. Replace it.

|
•
|
Thoroughly clean all parts to
assembled. |
•
|
Before installing the parts, apply fresh
engine oil to all sliding and rotating
surfaces. |
•
|
Replace all gaskets, O-rings and oil
seals with new
parts. | |
1. |
Assemble piston and connecting
rod.
(1) |
Use a hydraulic press for
installation. |
(2) |
The piston front mark and the connecting
rod front mark must face the timing belt side of the
engine.

| |
2. |
Install piston rings.
(1) |
Install the oil ring spacer and 2 side
rails by hand. |
(2) |
Using a piston ring expander, install
the 2 compression rings with the code mark facing
upward. |
(3) |
Position the piston rings so that the
ring ends are as shown.

| |
3. |
Install connecting rod bearings.
(1) |
Align the bearing claw with the groove
of the connecting rod or connecting rod
cap. |
(2) |
Install the bearings(A) in the
connecting rod and connecting rod cap(B).

| |
4. |
Install main bearings.
Upper 1,2,4,5 bearings have an oil
groove of oil holes; Lower bearings do
not. |
(1) |
Align the bearing claw with the claw
groove of the cylinder block, push in the 5 upper
bearings(A).

|
(2) |
Align the bearing claw with the claw
groove of the main bearing cap, and push in the 5 lower
bearings. | |
5. |
Install thrust bearings.
Install the 2 thrust bearings(A) under the
No.3 journal position of the cylinder block with the oil grooves
facing outward.

|
6. |
Place crankshaft on the cylinder
block. |
7. |
Place main bearing caps on cylinder
block. |
8. |
Install main bearing cap bolts.
Tightening
torque
Main bearing cap bolt
27.5 ~ 31.4Nm (2.8 ~ 3.2kgf.m, 20.3 ~
23.1lb-ft) + 60° ~ 64°
|
•
|
The main bearing cap bolts are
tightened in 2 progressive
steps. |
•
|
If any of the bearing cap bolts in
broken or deformed, replace
it. | |
(1) |
Apply a light coat of engine oil on the
threads and under the bearing cap
bolts. |
(2) |
Install and uniformly tighten the 10
bearing cap bolts(A), in several passes, in the sequence
shown.
Tightening torque : 29.4Nm
(3.0kgf.m, 21.7lb-ft)
|

|
(3) |
Retighten the bearing cap bolts by
60°~65° in the numerical order
shown. |
(4) |
Check that the crankshaft turns
smoothly. | |
9. |
Check crankshaft end
play. |
10. |
Install piston and connecting rod
assemblies.
Before installing the pistons, apply a
coat of engine oil to the ring grooves and cylinder
bores. |
(1) |
Remove the connecting rod caps, and slip
short sections of rubber hose over the threaded ends of the
connecting rod bolts. |
(2) |
Install the ring compressor, check that
the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a
hammer. |
(3) |
Stop after the ring compressor pops
free, and check the connecting rod-to-check journal alignment
before pushing the piston into
place. |
(4) |
Apply engine oil to the bolt threads.
Install the rod caps with bearings, and torque the nuts : 49.0
~ 52.0Nm (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)
Maintain downward force on the
ring compressor to prevent the rings from expanding
before entering the cylinder
bore. |

| |
11. |
Install a new gasket and rear oil seal case(A)
with 5 bolts(B).
Tightening
torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

Check that the mating surfaces are clean
and dry. | |
12. |
Install rear oil seal.
(1) |
Apply engine oil to a new oil seal
lip. |
(2) |
Using SST(09231-21000) and a hammer, tap
in the oil seal until its surface is flush with the rear oil
seal retainer edge.

| |
14. |
Install oil screen.
Install a new gasket(A) and oil screen(B) with
2 bolts(C).
Tightening
torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~
15.9lb-ft)
|

|
15. |
Install oil pan.
(1) |
Using a razor blade and gasket scraper,
remove all the old packing material from the gasket
surfaces.
Check that the mating surfaces are
clean and dry before applying liquid
gasket. | |
(2) |
Apply liquid gasket as an even bead,
centered between the edges of the mating surface.
Use liquid gasket MS 721-40A or
equivalent.
• |
To prevent leakage of oil,
apply liquid gasket to the inner threads of the
bolt holes. |
• |
Do not install the parts if
five minutes or more have elapsed since applying
the liquid gasket. Instead, reapply liquid gasket
after removing the
residue. |
• |
After assembly, wait at
least 30 minutes before filling the engine with
oil. | | |
(3) |
Install the oil pan(A) with the 19
bolts.
Uniformly tighten the bolts in several
passes.
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7. ~
8.7lb-ft)
|

| |
17. |
Install oil pressure sensor.
(1) |
Apply adhesive to 2 or 3
threads.
Adhesive : MS 721-39(B) or
equivalent. |
(2) |
Install the oil pressure sensor
(A).
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m,
10.8 ~ 15.9lb-ft)
|

| |
18. |
Install knock sensor(A).
Tightening
torque
16.7 ~ 26.5Nm (1.7 ~ 2.7kgf.m, 12.3 ~
19.5lb-ft)
|

|
19. |
Install oil level gauge assembly.
(1) |
Install a new O-ring on the oil level
gauge. |
(2) |
Apply engine oil on the
O-ring. |
(3) |
Install the oil level gauge assembly(A)
with the bolt.
Tightening torque
11.8 ~ 14.7Nm (1.2 ~ 1.5kgf.m, 8.7
~ 10.8lb-ft)
|

| |
20. |
Install cylinder
head. |
23. |
A/T : Install drive plate.
Tightening
torque
117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8
~ 94.0lb-ft)
| |
24. |
M/T : Install flywheel.
Tightening
torque
117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8
~ 94.0lb-ft)
| | |