1. |
M/T : remove
flywheel. |
2. |
A/T : remove drive
plate. |
3. |
Attach the engine to an engine stand for
disassembly. |
4. |
Remove timing chain. (Refer to Timing system
in this group) |
5. |
Remove cylinder head. (Refer to Cylinder block
in this group) |
6. |
Remove the oil dip stick (A).

|
7. |
Remove knock sensor(A).

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

|
9. |
Remove the sensor cover and the CKP
sensor(A).

|
11. |
Remove balance shaft module (oil
pump). |
12. |
Remove ladder frame(A).

|
13. |
Check the connecting rod end
play. |
14. |
Remove the connecting rod caps and check oil
clearance. |
15. |
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 crankshaft bearing cap and check oil
clearance. |
17. |
Check the crankshaft end
play. |
18. |
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. |

|
19. |
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. |
20. |
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. | | |
21. |
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 :
0.35mm(0.0138in.)
|

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
bolts. |
(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 bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m,
13.0~15.9lb-ft) + 88~92°
|
Do not turn the
crankshaft. | |
(7) |
Remove 2 bolts, connecting rod cap and
bearing half. |
(8) |
Measure the plastigage at its widest
point.
Standard
oil clearance
0.031 ~ 0.045mm (0.0012 ~
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
|
51.000 ~ 51.006mm (2.0079 ~ 2.0081in.)
|
b
|
B
|
51.006 ~ 51.012mm (2.0081 ~ 2.0083in.)
|
c
|
C
|
51.012 ~ 51.018mm (2.0083 ~
2.0085in.)
|
Crankshaft Pin
Mark Location Discrimination Of Crankshaft

Conform to read stamping order as
shown arrow direction from
#1. |
Discrimination Of Crankshaft
Class
|
Mark
|
Outside Diameter Of
Pin
|
I
|
1
|
47.966 ~ 47.972mm (1.8884 ~ 1.8886in.)
|
II
|
2
|
47.960 ~ 47.966mm (1.8881 ~ 1.8884in.)
|
III
|
3
|
47.954 ~ 47.960mm (1.8879 ~
1.8881in.)
|
Place Of
Identification Mark (Connecting Rod Bearing) Discrimination Of
Connecting Rod Bearing

Discrimination Of Connecting Rod Bearing
Class
|
Mark
|
Thickness Of
Bearing
|
AA
|
Blue
|
1.515 ~ 1.518mm (0.0596 ~ 0.0597in.)
|
A
|
Black
|
1.512 ~ 1.515mm (0.0595 ~ 0.0596in.)
|
B
|
None
|
1.509 ~ 1.512mm (0.0594 ~ 0.0595in.)
|
C
|
Green
|
1.506 ~ 1.509mm (0.0592 ~ 0.0594in.)
|
D
|
Yellow
|
1.503 ~ 1.506mm (0.0591 ~
0.0592in.)
|
|
(11) |
Selection
Crankshaft
Indentification Mark
|
Connecting Rod
Identification Mark
|
Assembing
Classification Of Bearing
|
I (1)
|
a
(A)
|
D
(Yellow)
|
b
(B)
|
C
(Green)
|
c
(C)
|
B
(None)
|
II (2)
|
a
(A)
|
C
(Green)
|
b
(B)
|
B
(None)
|
c
(C)
|
A
(Black)
|
III (3)
|
a
(A)
|
B
(None)
|
b
(B)
|
A
(Black)
|
c
(C)
|
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
14.7Nm (1.5kgf.m, 10.8lb-ft) +
27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) +
120~125°
|
Do not turn the
crankshaft. | |
(5) |
Remove the cap and bearing again, and
measure the widest part of the plastigage.
Standard
oil clearance
0.020 ~ 0.038mm (0.0008 ~
0.0015in.)
|

|
(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 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
|
56.000 ~
56.006mm (2.2047 ~
2.2049in.)
|
b
|
B
|
56.006 ~
56.012mm (2.2049 ~
2.2052in.)
|
c
|
C
|
56.012 ~
56.018mm (2.2052 ~
2.2054in.)
|
Crankshaft Journal
Mark Location Discrimination Of Crankshaft

Conform to read stamping order as shown
arrow direction from #1. |
Discrimination Of Crankshaft
Class
|
Mark
|
Outside Diameter Of
Journal
|
I
|
1
|
51.954 ~
51.960mm (2.0454 ~
2.0456in.)
|
II
|
2
|
51.948 ~
51.954mm (2.0452 ~
2.0454.)
|
III
|
3
|
51.942 ~
51.948mm (2.0449 ~
2.0452in.)
|
Place Of
Identification Mark (Crankshaft Bearing) Discrimination Of
Crankshaft Bearing

Discrimination Of Crankshaft Bearing
Class
|
Mark
|
Thickness Of
Bearing
|
AA
|
Blue
|
2.026 ~
2.029mm (0.0797 ~
0.0798in.)
|
A
|
Black
|
2.023 ~
2.026mm (0.0796 ~
0.0797in.)
|
B
|
None
|
2.020 ~
2.023mm (0.0795 ~
0.0796in.)
|
C
|
Green
|
2.017 ~
2.020mm (0.0794 ~
0.795in.)
|
D
|
Yellow
|
2.014 ~
2.017mm (0.0793 ~
0.0794in.)
|
Selection
Crankshaft Identification
Mark
|
Crankshaft Bore
Identification Mark
|
Assembling Classification
Of Bearing
|
I (1)
|
a
(A)
|
D
(Yellow)
|
b
(B)
|
C
(Green)
|
c
(C)
|
B
(None)
|
II (2)
|
a
(A)
|
C
(Green)
|
b
(B)
|
B
(None)
|
c
(C)
|
A
(Black)
|
III (3)
|
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
0.07 ~ 0.25mm (0.0027 ~
0.0098in.)
Limit : 0.30mm
(0.0118in.)
|

If the end play is greater than maximum,
replace the thrust bearings as a set.
Thrust bearing
thickness
1.925 ~ 1.965mm(0.0758 ~
0.07736in.)
| |
5. |
Inspect main journals and crank
pins
Using a micrometer, measure the diameter of
each main journal and crank pin.
Main journal
diameter : 51.942 ~ 51.960mm (2.0449 ~
2.0456in.)
Crank pin
diameter : 47.954 ~ 47.972mm (1.8879 ~
1.8886in.)
|

|
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 0.05mm(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
[2.4] : 88.00 ~ 88.03mm (3.4645 ~
3.4657in.)
[2.0] : 86.00 ~ 86.03mm (3.3858 ~
3.3870in.)
|

Measure position(from the bottom of the
cylinder block)
:
110.7mm(4.3582in.)/160mm(6.2992in.)/210mm(8.2677in.) | |
6. |
Check the cylinder bore size code on the
cylinder block.

Cylinder Bore Inner Diameter
Size Code
|
2.0
|
2.4
|
A
|
86.00 ~
86.01mm (3.3858~
3.3862in.)
|
88.00 ~
88.01mm (3.4645~
3.4649in.)
|
B
|
86.01 ~
86.02mm (3.3862~
3.3866in.)
|
88.01 ~
88.02mm (3.4649~
3.4653in.)
|
C
|
86.02 ~
86.03mm (3.3866~
3.3870in.)
|
88.02 ~
88.03mm (3.4653~
3.4657in.)
|
|
7. |
Check the piston size code on the piston top
face.

Stamp the grade mark of basic diameter
with rubber stamp. |
Piston Outer Diameter
Size Code
|
2.0
|
2.4
|
A
|
85.975 ~
85.985mm (3.3848~
3.3852in.)
|
87.975 ~
87.985mm (3.4635~
3.4639in.)
|
B
|
85.985
~85.995mm (3.3852~
3.3856in.)
|
87.985 ~
87.995mm (3.4639~
3.4643in.)
|
C
|
85.995 ~
86.005mm (3.3856~
3.3860in.)
|
87.995
~88.005mm (3.4643~
3.4647in.)
|
|
8. |
Select the piston related to cylinder bore
class.
Clearance
: 0.015 ~ 0.035mm (0.00059 ~
0.00137in.)
| |
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 34.5 mm (1.35 in.) from the top land of the
piston.
Standard
diameter
[2.4] : 87.975 ~ 88.005mm (3.4635 ~
3.4647in.)
[2.0] : 85.975 ~ 86.005mm (3.3848 ~
3.3860in.)
|

|
3. |
Calculate the difference between the cylinder
bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.015 ~ 0.035mm(0.00059 ~
0.00137in.)
| |
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
Standard
No.1 : 0.05 ~ 0.08mm (0.0019 ~
0.0031in.)
No.2 : 0.04 ~ 0.08mm (0.0015 ~
0.0031in.)
Oil ring : 0.06 ~ 0.15mm (0.0023 ~
0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm
(0.008in.)
|

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 : 0.15 ~ 0.30mm (0.0059 ~
0.0118in.)
No.2 : 0.37 ~ 0.52m (0.0145 ~
0.0204in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~
0.0275in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm
(0.0315in.)
|

|
Piston Pins
1. |
Measure the diameter of the piston
pin.
Piston pin
diameter
21.001 ~ 21.006mm (0.8268 ~
0.8270in.)
|

|
2. |
Measure the piston pin-to-piston
clearance.
Piston
pin-to-piston clearance
0.013 ~ 0.023mm (0.0005 ~
0.0009in.)
| |
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.)
| |
•
|
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) |
Before pressing the piston pin, apply a
coat of lubricant oil to the piston pin outer and connecting
rod.
• |
Take care that piston pin is
not to be damaged during pressing
process. |
• |
When replace the piston pin,
check the piston pin outer diameter and connecting
rod small end inner diameter as
below. | |
Piston
pin outer DIA. :
21.001 ~ 21.006mm (0.8268 ~
0.8270in)
Connecting rod small end inner DIA.
:
20.974 ~ 20.985mm (0.8257 ~
0.8261in)
Interference:
-0.032 ~ -0.016 mm (-0.0013 ~
-0.0006 in.)
| |
(2) |
Use a hydraulic press for
installation. |
(3) |
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 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(A) on the cylinder
block.

|
7. |
Place main bearing caps on cylinder
block. |
8. |
Install main bearing cap bolts.
Always use new main bearing cap
bolts. |
•
|
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
14.7Nm (1.5kgf.m, 10.8lb-ft) +
27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) +
120~125°
|

|
(3) |
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
bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m,
13.0~15.9lb-ft) + 88~92°
|
Always use new connecting rod cap
bolts. |
Maintain downward force on the
ring compressor to prevent the rings from expanding
before entering the cylinder
bore. |

| |
11. |
Apply liquid gasket to the mating surface of
cylinder block and ladder frame.
•
|
Be assembling ladder frame, the
liquid sealant Loctite 5900 or THREEBOND 1217H should be
applied ladder frame. |
•
|
The part must be assembled within
5 minutes after sealant was
applied. |
•
|
Apply sealant to the inner threads
of the bolt
holes. | |

|
12. |
Install ladder frame(A) with 10 bolts in
several passes in sequence shown.
Tightening
torque
Step 1 : 8.8 ~ 9.8N.m (0.9 ~ 1.0kgf.m,
6.5 ~ 7.2lb-ft)
Step 2 : 17.7 ~20.6N.m (1.8 ~ 2.1kgf.m,
3.0 ~ 15.2lb-ft)
Step 3 : 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m,
20.3 ~ 23.1lb-ft)
|


|
13. |
Install rear oil seal.
(1) |
Apply engine oil to a new oil seal
lip. |
(2) |
Using SST(09231-H1100, 09214-3K100) and
a hammer, tap in the oil seal until its surface is flush with
the rear oil seal retainer
edge. | |
14. |
Install balance shaft module (oil pump).
|
16. |
Install CKP sensor(A) and sensor
cover.
Tightening
torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
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
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8
~ 8.7lb-ft)
|

| |
18. |
Install knock sensor(A).
Tightening
torque
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~
17.4lb-ft)
|

|
19. |
Install oil level gauge assembly.
(1) |
Install a new O-ring on the oil dip
stick. |
(2) |
Apply engine oil on the
O-ring. |
(3) |
Install the oil dip stick (A) with the
bolt.
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8
~ 8.7lb-ft)
|

| |
20. |
Install the cylinder head. (Refer to Cylinder
head assembly in this group) |
21. |
Install the timing chain. (Refer to Timing
system in this group) |
22. |
Install the oil pan.
(1) |
Using a razor blade and gasket scraper,
remove all the old gasket 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 LOCTITE5900H or
THREEBOND 1217H or equivalent(MS721-40).
Bead
width : 3.0mm
(0.12in)
|

• |
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).
Uniformly tighten the bolts in several
passes.
Tightening torque
M9(B):30.4 ~ 34.3N.m (3.1 ~
3.5kgf.m, 22.4 ~ 25.3lb-ft)
M6(C):9.8 ~ 11.8N.m (1.0 ~
1.2kgf.m, 7.2 ~ 8.7lb-ft)
|

| |
24. |
A/T : Install drive plate(A).
Tightening
torque
117.7 ~ 127.5N.m (12 ~ 13kgf.m, 86.8 ~
94.0lb-ft)
|
M/T : Install flywheel(B).
Tightening
torque
117.7 ~ 127.5N.m (12 ~ 13kgf.m, 86.8 ~
94.0lb-ft)
|

•
|
Always use new flywheel(drive
plate) bolts(C). |
•
|
Apply sealant to the screw
part(8mm from the end of the bolt) when using new
flywheel bolts.
Sealant : Three bond 2403, Loctite 200 or
204
|

|
•
|
Install and uniformly tighten the
7 bolts, in several
passes. | | | |