Water Jacket Insert

Components and components location

Repair procedures

2.	Remove the RH water jacket insert and LH water jacket insert (A). • When removing the water jacket insert, Be careful not to damage the top surfaces of the cylinder block.

3.

Install in the reverse order of removal. • Always use a new water jacket insert. • Install the upper surface of the water jacket insert below the upper surface of the cylinder block. • When installing water jacket insert, check LH, RH classification and installing direction. • When installing a new water jacket insert, check the lip seal (A) and the cylinder block mounting surface for foreign matters. • When installing a new water jacket insert, do not press the sus spring (A).

Fly Wheel

Repair procedures

2.	Remove the fly wheel (A). Tightening torque : 71.5 - 75.5 N.m (7.3 - 7.7 kgf.m, 52.8 - 55.6 lb-ft) • Always use a new fly wheel mounting bolts.

Rear Oil Seal

Components and components location

Repair procedures

4.	Using SSTs (09231-H1100, 09231-2B200), install the new rear oil seal. When assembling, the surface of the oil seal shall coincide with the surface of the cylinder block. • Always use a new rear oil seal.

Piston and Connecting Rod

Repair procedures

• Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring connector and hoses to avoid misconnection. • To release the fuel system pressure before removing the engine assembly, start the engine without fuel pump relay. Then, switch "OFF" the ignition when engine stops.

4.	Remove the cylinder head. (Refer to Cylinder Head Assembly - "Cylinder Head") • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

7.

Remove the piston and connecting rod assembly. (1) Using a ridge reamer, remove all the carbon from the top of the cylinder. (2) Remove the connecting rod bearing caps (A). • Mark the connecting rod, and caps to be able to reassemble in the original position and direction. (3) Push the piston and connecting rod assembly (A) with upper bearing through the top of the cylinder block. • Keep the connecting rod ands cap with their bearings assembled together. • Arrange the piston and connecting rod assemblies in the correct order.

2.

Check the connecting rod bearing oil clearance. (1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly. (2) Remove the 2 connecting rod cap bolts. (3) Remove the connecting rod cap and lower bearing. (4) Clean the crankshaft pin journal and bearing. (5) Place a plasticgauge across the crankshaft pin journal. (6) Reinstall the lower bearing and connecting rod cap, and torque the bolts. Tightening torque : 17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft) + 68° - 72° • Do not turn the crankshaft. (7) Remove the connecting rod cap. (8) Measure the plasticgauge at its widest point. Bearing oil clearance : 0.037 - 0.055 mm (0.0015 - 0.0022 in.) (9) If the measurement from the plasticgauge is too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. Recheck the oil clearance. • Do not file, shim, of scrape the bearings or the caps to adjust clearance. (10) If the plasticgauge shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance. • 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 Identification Mark Identification Of Connecting Rod Class Mark Connecting rod big-end inner diameter A 0 45.000 - 45.006 mm (1.7717 - 1.7719 in.) B 1 45.006 - 45.012 mm (1.7719 - 1.7721 in.) C 2 45.012 - 45.018 mm (1.7721 - 1.7724 in.) Crankshaft Pin Outside Diameter Identification Mark Identification Of Crankshaft Pin Outside Diameter Class Mark Crankshaft pin journal outer diameter Ⅰ 1 41.972 - 41.966 mm (1.6524 - 1.6522 in.) II 2 41.966 - 41.960 mm (1.6522 - 1.6520 in.) III 3 41.960 - 41.954 mm (1.6520 - 1.6517 in.) Connecting Rod Bearing Identification Mark Discrimination of Connecting Rod Bearing Class Color Connecting rod bearing thickness A Blue 1.510 - 1.513 mm (0.0594 - 0.0596 in.) B Black 1.507 - 1.510 mm (0.0593 - 0.0594 in.) C None 1.504 - 1.507 mm (0.0592 - 0.0593 in.) D Green 1.501 - 1.504 mm (0.0591 - 0.0592 in.) E Red 1.498 - 1.501 mm (0.0590 - 0.0591 in.) (11) Use the bearing selection table below to select a suitable connecting rod bearing. Connecting Rod Bearing Selection Table Connecting Rod Identification Mark A B C Crankshaft Pin Journal Indentification Mark 1 E (Red) D (Green) C (None) 2 D (Green) C (None) B (Black) 3 C (None) B (Black) A (Blue)

3.

Check the 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 : 0.05 mm (0.0020 in.) / 100 mm (3.94 in.) Allowable twist of connecting rod : 0.1 mm (0.0039 in.) / 100 mm (3.94 in.) • When the connecting rods installed without bearings, there should be no difference on side surface.

1.	Clean the 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. • Do not use a wire brush.

• Thoroughly clean all parts to assembled. • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. • Always use new gaskets, O-ring and oil seals.

1.

Assemble the piston and the connecting rod. (1) Install the snap ring (A) in one side of the piston pin hole. (2) Align the piston front mark (A) and the connecting rod front mark (B). (3) Insert the piston pin (A) into the piston pin hole and the small end bore of connecting rod. (4) Install the snap ring (B) in the other side after inserting the piston pin. • Before inserting the piston pin, apply sufficient engine oil on the piston’s outer surface, piston hole’s inner surface and connecting rod’s small-end bore. • When inserting, use caution not to damage or scratch the connecting rods’ small-end hole, piston’s pin hole and piston pin. • Install the snap ring surely so that the snap ring contacts the overall groove of the piston’s pin hole. • Assemble so that the cut surface of the snap ring is located within the upper 45° range.

2.

Install the piston rings. (1) Install the oil ring expander and two side rails by hand. (2) Using a piston ring expander, install the 2 compression rings with the maker mark facing upward. (3) Position the piston rings so that the ring ends are as shown. • The side rail is an asymmetric barrel type and install it so that DMC mark faces upward (Cylinder head side). At this time, paint identification mark should be positioned at the right side of ring cutting section.

4.

Install the piston and connecting rod assembly. • Before installing the piston, apply a coat of engine oil to the piston ring grooves and cylinder bores. • The piston front mark (A) and the connecting rod front mark (B) must face the timing chain side of the engine. (1) Install the ring compressor, check that the rings are 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-crank journal alignment before pushing the piston into place. • Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore. (3) Install the connecting rod caps (A) with bearings, and tighten the bolts. Tightening torque : 17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft) + 68 - 72° • Always use new connecting rod cap bolts.

Crankshaft

Repair procedures

• Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring connector and hoses to avoid misconnection. • To release the fuel system pressure before removing the engine assembly, start the engine without fuel pump relay. Then, switch "OFF" the ignition when engine stops. • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1.

Check the crankshaft bearing oil clearance. (1) Clean each main journal and lower bearing with a clean shop towel. (2) Place one strip of plastcigauge across each main journal. (3) Reinstall the bearing caps with their lower bearings, then tighten the bolts. Tightening torque : Crank lower case mounting bolts : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft) Bearing cap mounting bolts : 27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft) + 118 - 122° [Crank lower case mounting bolts] [Bearing cap mounting bolts] • Do not turn the crankshaft. (4) Remove the lower crankcase, and measure the widest part of the plasticgauge. Bearing oil clearance : 0.030 - 0.048 mm (0.0012 - 0.0019 in.) (5) If the plasticgauge measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark (select the color as shown in the next column). Recheck the oil clearance. • Do not file, shim, of scrape the bearings or the caps to adjust clearance. (6) If the plasticgauge shows that 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 plasticgauge shows that 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 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. Cylinder Block Crankshaft Journal Bore Mark Location Letters have been stamped on the side surface of the block as a mark for the size of each of the 5 main journal bores. Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings. Class Mark Cylinder block crankshaft journal bore inner diameter a A 50.000 - 50.006 mm (1.9685 - 1.9687 in.) b B 50.006 - 50.012 mm (1.9687 - 1.9690 in.) c C 50.012 - 50.018 mm (1.9690 - 1.9692 in.) Crankshaft Main Journal Mark Location Discrimination Of Crankshaft Main Journal Class Mark Crankshaft main journal outer diameter Ⅰ 1 44.954 - 44.960 mm (1.7698 - 1.7701 in.) II 2 44.948 - 44.954 mm (1.7696 - 1.7698 in.) III 3 44.942 - 44.948 mm (1.7694 - 1.7696 in.) Crankshaft Bearing Identification Mark Location [No. 2, No. 4 Journal Upper Bearing] [No. 1, No. 3, No. 5 Journal Upper Bearing] [Lower Bearing] Discrimination Of Crankshaft Bearing Class Color Bearing thickness A Blue 2.524 - 2.527 mm (0.0994 - 0.0995 in.) B Black 2.521 - 2.024 mm (0.0993 - 0.0797 in.) C None 2.518 - 2.521 mm (0.0991 - 0.0993in.) D Green 2.515 - 2.518 mm (0.0990 - 0.0991 in.) E Red 2.512 - 2.515 mm (0.0989 - 0.0990 in.) (7) Select the bearing by using selection table. Crankshaft Main Bearing Selection Table Main journal bore Identification Mark a (A) b (B) c (C) Crank shaft main journal mark I (1) E (Red) D (Green) C (None) II (2) D (Green) C (None) B (Black) III (3) C (None) B (Black) A (Blue)

• Thoroughly clean all parts to assembled. • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. • Always use new gaskets, O-ring and oil seals.

2.

Install the main bearing. • When installing the crankshaft upper bearings, the upper bearings should fit for each journal. [No. 2, No. 4 Journal Upper Bearing] [No. 1, No. 3, No. 5 Journal Upper Bearing] (1) Align the bearing claw with the groove of the cylinder block, and push in the 5 upper bearings (A). (2) Align the bearing claw with the groove of the crank lower case, and push in the 5 lower bearings (A). (3) Apply a coat of engine oil after assembling the main bearings.

4.

Place the crankshaft (A) on the cylinder block. • When exchanging the crankshaft and short engine, apply if the pilot bearing is not assembled. [DCT Only] • When press fitting the pilot bearing, press fit so that the load is applied only to the outer race of the pilot bearing. - if load is applied to the seal and inner race, the component or bearing inside may be damaged. • Press-fit depth of the pilot bearing (A) : 1.5 - 2.0 mm (0.0591 - 0.0787 in) from the end of the crankshaft.

5.

Install the lower crankcase. (1) Make sure to remove hardened sealant, foreign matters, oil, dust, moisture on the sealing face of the liquid gasket of the lower crankcase. Spray the cleaner on the sealing surface and wipe it off with a clean cloth. (2) Install the new O-ring (A) on the cylinder block. (3) Apply liquid sealant on lower crankcase. Then, assemble the part within 5 minutes of applying sealant. Width : 2.5 - 3.5 mm (0.0984 - 0.1378 in) Specification : MS721-40AA or AAO / above. (4) Tighten the crankshaft bearing cap bolts several times according to the tightening sequence shown below. Tightening torque : 27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft) + 118 - 122° • Always use new bearing cap bolts. (5) Tighten the lower crankcase mounting bolts several times according to the tightening sequence shown below. Tightening torque : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft) (6) Install the rear caps (A). • When installing the rear cap, make sure that the cylinder block installed surface and the rear cap installed surface are aligned. (1) Check that the crankshaft turns smoothly.

8.	Assemble the other parts in the reverse order of disassembly. • In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according to the pin journal mark on the crankshaft. • Connecting rod bearing selection (Refer to Cylinder Block - "Piston and Connecting Rod")

Cylinder Block

Repair procedures

• Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring connector and hoses to avoid misconnection. • To release the fuel system pressure before removing the engine assembly, start the engine without fuel pump relay. Then, switch "OFF" the ignition when engine stops. • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

• Thoroughly clean all parts to assembled. • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. • Always use new gaskets, O-ring and oil seals.

8.

Assemble the other parts in the reverse order of disassembly. • In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block. • Crankshaft main bearing selection (Refer to Cylinder Block - "Crankshaft") • Piston selection (Refer to Cylinder Block - "Piston and Connecting Rod")