| •
|
Use fender covers to avoid damaging
painted surfaces. |
| •
|
To avoid damage, unplug the wiring
connectors carefully while holding the connector
portion. | |
| •
|
Mark all wiring and hoses to avoid
misconnection. |
| •
|
Inspect the timing belt before removing
the cylinder head. |
| •
|
Turn the crankshaft pulley so that the
No.1 piston is at top dead
center. |
| •
|
Engine removal is required for this
procedure. | |
| 1. |
Remove the exhaust
manifold. |
| 2. |
Remove the intake
manifold. |
| 3. |
Remove the timing
chain. |
| 4. |
Remove the water temperature control
assembly. |
| 5. |
Remove the cylinder
head. |
| 7. |
Remove the oil filter
assembly. |
| 8. |
Remove the A/C compressor(A) from
engine.
|
| 9. |
Remove the alternator(A) from
engine.
|
| 10. |
Remove the power steering pump from
engine.
(Refer to Power steering oil pump in ST
Group.) |
| 1. |
Remove the drive
plate. |
| 2. |
Remove the knock sensor(A).
|
| 3. |
Remove the upper oil pan(A).
|
| 4. |
Remove the baffle plate(A).
|
| 5. |
Remove the rear oil seal case(A).
|
| 6. |
Remove the oil drain cover(A).
|
| 7. |
Check the connecting rod end
play. |
| 8. |
Check the connecting rod cap oil
clearance. |
| 9. |
Remove the 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. | | |
| 10. |
Remove the crankshaft main bearing cap and
check oil clearance. |
| 11. |
Check the crankshaft end
play. |
| 12. |
Lift the crankshaft(A) out of engine, being
careful not to damage journals.
|
Arrange the main bearings and thrust
bearings in the correct
order. | |
| 13. |
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 piston and piston pin
as a set. |
| 14. |
Remove the piston rings.
| (1) |
Using a piston ring expander, remove the
2 compression rings. |
| (2) |
Remove 2 side rails and the spacer by
hand. |
|
Arrange the piston rings in the correct
order
only. | |
| 15. |
Disconnect connecting rod from
piston.
Using a press, remove the piston pin from the
piston.
(Press-in load : 800 ~ 1400kg (1764 ~
3086lb) |
| 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.)
|
| A. |
If out-of-tolerance, install a new
connecting rod. |
| B. |
If still out-of-tolerance, replace the
crankshaft. | |
| 2. |
Check the connecting rod 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
bearinghalf. |
| (8) |
Measure the plastigage at its widest
point.
Standard
oil clearance
0.038 ~ 0.056mm(0.0015 ~
0.0022in.)
|
|
| (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
Identification Of Connecting Rod
Class
|
Mark
|
Inside
Diameter
|
0
|
a
|
58.000 ~ 58.006mm
(2.2834 ~ 2.2837in.)
|
1
|
b
|
58.006 ~ 58.012mm
(2.2837 ~ 2.2839in.)
|
2
|
c
|
58.012 ~ 58.018mm
(2.2839 ~
2.2842in.)
|
Crankshaft Pin
Mark Location
Identification
of Crankshaft
Discrimination of Crankshaft
Class
|
Mark
|
Outside Diameter of
Pin
|
I
|
1 or A
|
54.966 ~ 54.972mm
(2.1640 ~ 2.1642in.)
|
II
|
2 or B
|
54.960 ~ 54.966mm
(2.1638 ~ 2.1640in.)
|
III
|
3 or C
|
54.954 ~ 54.960mm
(2.1635 ~
2.1638in.)
|
Place of
Identification Mark (Connecting Rod Bearing)
Upper
Lower
Identification of Connecting Rod Bearing
Class
|
Mark
|
Thickness of
Bearing
|
E
|
Blue
|
1.514 ~ 1.517mm
(0.0596 ~ 0.0597in.)
|
D
|
Black
|
1.511 ~ 1.514mm
(0.0595 ~ 0.0596in.)
|
C
|
Brown
|
1.508 ~ 1.511mm
(0.0594 ~ 0.0595in.)
|
B
|
Green
|
1.505 ~ 1.508mm
(0.0593 ~ 0.0594in.)
|
A
|
Yellow
|
1.502 ~ 1.505mm
(0.0591 ~
0.0593in)
|
|
| (11) |
Selection
|
Connecting Rod
Identification Mark
|
0(a)
|
1(b)
|
2(c)
|
Crankshaft
Indentification Mark
|
1 or A
|
A
(Yellow)
|
B
(Green)
|
C
(Brown)
|
2 or B
|
B
(Green)
|
C
(Brown)
|
D
(Black)
|
3 or C
|
C
(Brown)
|
D
(Black)
|
E
(Blue)
|
| |
| 3. |
Check the crankshaft bearing oil
clearance.
| (1) |
To check main bearing-to-journal oil
clearance, remove the main bearing 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
49.00Nm(5.0 kgf.m, 36.16lb-ft) +
90°
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+
120°
29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m,
21.70 ~ 23.14lb-ft)
|
|
Do not turn the
crankshaft. | |
| (5) |
Remove the cap and bearing again, and
measure the widest part of the plastigage.
Standard
oil clearance
0.022 ~ 0.040mm (0.0009 ~
0.0016in.)
|
|
| (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. |
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
Class
|
Mark
|
Inside
Diameter
|
a
|
A
|
73.500 ~ 73.506mm
(2.8937 ~ 2.8939in.)
|
b
|
B
|
73.506 ~ 73.512mm
(2.8939 ~ 2.8942in.)
|
c
|
C
|
73.512 ~ 73.518mm
(2.8942 ~
2.8944in.)
|
Crankshaft
Journal Mark Location
Discrimination
of Crankshaft
Discrimination of Crankshaft
Class
|
Mark
|
Outside Diameter of
Journal
|
I
|
1 or A
|
68.954 ~ 68.960mm
(2.7147 ~ 2.7150in.)
|
II
|
2 or B
|
68.948 ~ 68.954mm
(2.7145 ~ 2.7147in.)
|
III
|
3 or C
|
68.942 ~ 68.948mm
(2.7142 ~
2.7145in.)
|
Place of
Identification Mark (Crankshaft Bearing)
Discrimination of Crankshaft Bearing
Class
|
Mark
|
Thickness of
Bearing
|
E
|
Blue
|
2.277 ~ 2.280mm
(0.0896 ~ 0.0897in.)
|
D
|
Black
|
2.274 ~ 2.277mm
(0.0895 ~ 0.0896in.)
|
C
|
Brown
|
2.271 ~ 2.274mm
(0.0894 ~ 0.0895in.)
|
B
|
Green
|
2.268 ~ 2.271mm
(0.0893 ~ 0.0894in.)
|
A
|
Yellow
|
2.265 ~ 2.268mm
(0.0892 ~
0.0893in.)
|
Selection
|
Crankshaft Bore
Identification Mark
|
a(A)
|
b(B)
|
c(C)
|
Crankshaft
Identification Mark
|
1 or A
|
A
(Yellow)
|
B
(Green)
|
C
(Brown)
|
2 or B
|
B
(Green)
|
C
(Brown)
|
D
(Black)
|
3 or C
|
C
(Brown)
|
D
(Black)
|
E
(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
0.10 ~ 0.28mm (0.0039 ~
0.0110in.)
|
If the end play is greater than maximum,
replace the thrust bearings as a set.
Thrust bearing
thickness
2.41 ~ 2.45mm(0.0949 ~
0.0964in.)
| |
| 5. |
Inspect main journals and crank
pins
Using a micrometer, measure the diameter of
each main journal and crank pin.
Main journal
diameter :
68.942 ~ 68.960mm (2.7142 ~
2.7149in.)
Crank pin
diameter :
54.954 ~ 54.972mm (2.1635 ~
2.1642in.)
|
|
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
| |
Cylinder Block
| 1. |
Remove the gasket material.
Using a gasket scraper, remove all the gasket
material from the top surface of the cylinder
block. |
| 2. |
Clean the cylinder block
Using a soft brush and solvent, thoroughly
clean the cylinder block. |
| 3. |
Inspect the top surface of the 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.),Less than 0.02mm(0.0008in.) / 150 x
150
|
|
| 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
96.00 ~ 96.03mm (3.7795 ~
3.7807in.)
|
|
| 6. |
Check the cylinder bore size code on the
cylinder block.
Class
|
Size Code
|
Cylinder Bore Inner
Diameter
|
A
|
A
|
96.00~96.01mm
(3.7795 ~
3.7799in.)
|
B
|
B
|
96.01~96.02mm
(3.7799 ~
3.7803in.)
|
C
|
C
|
96.02~96.03mm
(3.7803 ~
3.7807in.)
|
|
| 7. |
Check the piston size code(A) and the front
mark(B) on the piston top face.
Class
|
Size Code
|
Piston Outer
Diameter
|
A
|
A
|
95.96 ~ 95.97mm
(3.7779
~ 3.7783in.)
|
B
|
B
|
95.97 ~ 95.98mm
(3.7783
~ 3.7787in.)
|
C
|
C
|
95.98 ~95.99mm
(3.7787 ~
3.7791in.)
|
|
| 8. |
Select the piston related to cylinder bore
class.
Clearance
: 0.03 ~ 0.05mm(0.0012 ~
0.0020in.)
| |
Piston And Rings
| 1. |
Clean piston
| (1) |
Using a gasket scraper, remove the
carbon from the piston top. |
| (2) |
Using a groove cleaning tool, 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 14 mm (0.5512 in.) from the bottom of the
piston.
Standard
diameter
95.96 ~ 95.99mm (3.7779~
3.7791in.)
|
|
| 3. |
Calculate the difference between the cylinder
bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.03 ~ 0.05mm(0.0012 ~
0.0020in.)
| |
| 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 : 0.03 ~ 0.07mm (0.0012 ~
0.0027in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~
0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~
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
replaced.
Piston ring
end gap
Standard
No.1 : 0.17 ~ 0.32mm (0.0067 ~
0.0126in.)
No.2 : 0.32 ~ 0.47m (0.0126 ~
0.0185in.)
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
23.001 ~ 23.006mm (0.9056 ~
0.9057in.)
|
|
| 2. |
Measure the piston pin-to-piston
clearance.
Piston
pin-to-piston clearance
0.009 ~ 0.017mm (0.0004 ~
0.0007in.)
| |
| 3. |
Check the difference between the piston pin
diameter and the connecting rod small end diameter.
Piston
pin-to-connecting rod interference
-0.032 ~ -0.017mm (-0.0012 ~
-0.0007in.)
| |
| •
|
Thoroughly clean all parts to be
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 the piston and the 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 the 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 the 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 the 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 4 upper
bearings(A).
|
| (2) |
Align the bearing claw with the claw
groove of the main bearing cap, and push in the 4 lower
bearings. | |
| 5. |
Install the 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 the crankshaft(A) on the cylinder
block.
|
| 7. |
Place the main bearing caps on cylinder
block. |
| 8. |
Install the main bearing cap
bolts.
| (1) |
Install and uniformly tighten the
bearing cap bolts, in several passes, in the sequence
shown.
Tightening torque
Main bearing cap bolt
49.00Nm(5.0 kgf.m, 36.16lb-ft) +
90° (1 ~ 8)
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+
120° (9 ~ 16)
29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m,
21.70 ~ 23.14lb-ft) (17 ~ 22)
|
| • |
Always use new main bearing
cap bolts. |
| • |
If any of the bearing cap
bolts are broken or deformed, replace
it. | |
Use the SST( 09221-4A000 ), install main
bearing cap bolts.
|
| (2) |
Check that the crankshaft turns
smoothly. | |
| 9. |
Check crankshaft end
play. |
| 10. |
Install the piston and connecting rod
assemblies.
|
Before installing the pistons, apply a
coat of engine oil to the ring grooves and cylinder
bores. |
| (1) |
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. |
| (2) |
Stop after the ring compressor pops
free, and check the connecting rod-to-check journal alignment
before pushing the piston into
place. |
| (3) |
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°
|
Use SST(09221-4A000), install connecting
rod bearing cap bolts.
| • |
Always use new connecting
rod bearing cap
bolts. |
| • |
Maintain downward force on
the ring compressor to prevent the rings from
expanding before entering the cylinder
bore. | |
| |
| 11. |
Check the connecting rod end
play. |
| 12. |
Install the oil drain cover(A).
Tightening
torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~
8.67lb-ft)
|
| •
|
Clean the sealing face before
assembling two parts. |
| •
|
Remove harmful foreign materials
on the sealing face before applying
sealant |
| •
|
Before assembling oil drain cover,
the liquid sealant TB1217H should be applied to the oil
drain cover. |
| •
|
The part must be assembled within
5 minutes after sealant was
applied. |
| •
|
Apply sealant to the inner threads
of the bolt
holes. | |
|
| 13. |
Install the rear oil seal
case(A).
Tightening
torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~
8.67lb-ft)
|
| •
|
Clean the sealing face before
assembling two parts. |
| •
|
Remove harmful foreign materials
on the sealing face before applying
sealant |
| •
|
Before assembling rear oil seal
case, the liquid sealant TB1217H should be applied to
the rear oil seal case. |
| •
|
The part must be assembled within
5 minutes after sealant was
applied. |
| •
|
Apply sealant to the inner threads
of the bolt
holes. | |
|
| 14. |
Using the SST(09231-3C200, 09231-H1100),
install rear oil seal.
|
| 15. |
Install the baffle plate.
Install and uniformly tighten the baffle plate
bolts, in several passes, in the sequence shown.
Tightening
torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~
8.68lb-ft)
|
|
| 16. |
Install the upper oil pan.
| A. |
Using a gasket scraper, remove all the
old packing material from the gasket
surfaces. |
| B. |
Before assembling the oil pan, the
liquid sealant TB1217H should be applied on upper oil
pan.
The part must be assembled within 5
minutes after the sealant was applied.
Bead
width :
2.5mm(0.1in.)
|
| • |
Clean the sealing face
before assembling two
parts. |
| • |
Remove harmful foreign
materials on the sealing face before applying
sealant |
| • |
When applying sealant
gasket, sealant must not protrude into the inside
of oil pan. |
| • |
To prevent leakage of oil,
apply sealant gasket to the inner threads of the
bolt
holes. | | |
| C. |
Install the upper oil pan.
Uniformly tighten the bolts in several
passes.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m,
7.23 ~ 8.68lb-ft)
|
| |
| 17. |
Install the knock sensor(A).
Tightening
torque
15.68 ~ 23.52Nm (1.6 ~ 2.4kgf.m, 11.57 ~
17.36lb-ft)
|
|
| 18. |
Install the drive plate.
Tightening
torque
71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 52.80 ~
55.69lb-ft)
| |
| 1. |
Install the power steering
pump. |
| 2. |
Install the
alternator. |
| 3. |
Install the air conditioner
compressor |
| 4. |
Install the oil filter
assembly. |
| 6. |
Install the cylinder
head. |
| 7. |
Install the water temperature control
assembly. |
| 8. |
Install the timing
chain. |
| 9. |
Install the intake
manifold. |
| 10. |
Install the exhaust
manifold. | |
