I

EngineBlock
SpeciafTools .............7-2 Cylinder Block
lllustratedlndex ...................................
7-3 lnspection ..............
7-13
Flywheel and Drive Plate BoreHoning ..........7-11
Replacement .........7-G Piston Pins
Connecting Rod and Crankshaft Removal .................
7-14
EndPlay .................
7-6 lnstallation .............
7-15
Main Bearings Inspection ..............
7-16
Cfearance -7
..,,,,,,,,,....7 Connecting Rods
Selection ................
7-8 Seleetion ................
7-15
Connecting Rod Bearings Piston Rings
^ Clearance ...............
7-B EndGap .................
7-17
|J Selection ................
7-9 Repfacement .........7-11
Pistons and Crankshaft Ring-to-GrooveClearance...............
7-18
Removal .................
7-9 Alignment ..............
7-18
Crankshaft Crankshaft Oil Seal
fnspection ..............7-11 Installation .............
7-19
Pistons Crankshaft
fnspection .,,,,.,,,....,7-12 fnstaffation .............7-2O
Installation .............
7-20 Oil Pan
fnstaffation .............7-22
Oil Seals
lnstaffation .............7-24
 SpecialTools

Raf. No. Tool Numbor DBcription (Ny I Pag6 Rotorence

o 07LAB- PV00100 RingGearHolder 1 7-6
@ 07749- 0010000 Driver 1 7 -19,25
@ 079i17- S800200 SealDriver 1 7-24
@ 07948- S800101 Driver Attachment 1 7-'t9,25
@ 07973- P800200 PilotCollar 1 7-141 ,5
@ 07973- PE00310 PistonPin DriverShaft I 7-14.15
o 07973- PE00320 Piston Pin Driver Head 1 l-14,15
o 0t913 - PE00400 Piston Pin Base lnsen

I
1 l - ' 1 4 ,1 5
@ 07973- S800100 Piston BaseHead 1 7 - 1 4 ,1 5
@ 07973- 6570500 Piston Base 1 7-'t4,15
@ 07973- 5570600 PistonBaseSpring 1 7-'t4.15

@ o @
\
o

0
o o

c,
@ @
L

t-1
!
lllustrated lndex

D16Y7engine:

Lrori""t" "tl internalpartswith engineoil during reassembly.

I
NOTE:
. Applyliquidgaskettothematingsurfaces
ofthe rightsidecoverandoil pumpcasebeforeinstalling
them.
. Use liquidgasket.part No. 08718- 0001or 08718- 0003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit. 6 x 1 . Om m
DRAINBOLT 12 N.m {1 .2 kgf.m,
44 N.m (4.5 kgf.m, 33 lbf.ftl 8 7 lbt'ftl
"i'.''
o[ rlt cnsrer
Hii,ilJ \ 'y" FLYwHEELcovER

6 x 1.0mm ,::::T:^I \\
12 N.m (1.2 kgt.m, 8.7 lbt.ft) y"::::-
ffi::: I $5./
fR..r'
OIL PAN .*"'" I gNliJ'J.f--
Refetto page7-22 ,t/,oksf'm,87
rbt'ttr
when installing. ><-BL %S
Apply liquidgasketto

@ff
these points.

1 1x 1 . 5m m
51 N.m
(5.2kgt m,3E
Applyengineoilto the bolt
threads.
NOT€: After torquing
each cap, turn the crankshaft
to checklor binding.

MAI BEARINGCAP
MAIN BEARINGS
Selection,page7-8
NOTE:New main bearingsmust
be selectedby rnatchingcrank
and block identilicationmarkings.
CRANKSHAFT
page7-'11
lnstallation,
6 x 1 . 0m m CRANKSHAFT OIL SEAL
1'l N.m (1.1 kgf.m, 8 lbf.ft) lnstallation,
pages7-19and 7-25
OII SCREEN
6 x 1.0 mm \{ePlace
1 1 N . m l 1 . 1 kgf.m, a lbt.tt) 6 x 1 . Om m
1'l N.m (l .1 kgf.m,
GASKET 8 tbt.ftl
Replace.
OIL PUMP RIGHTSIDECOVER
Overhaul.page8-9 DOWELPIN Apply liquidgasker
Removal/lnspection, to m6ting surface.
page8-10.
WASHERS
Groovedsides face outward.
NOTE:Ihrusr washerthickness
CRANKSHAFTSEAL /.\ is fixed and must not be changed
lnstallation,pages7-24--rS) BR€ATHINGPORT COVER by grindingor shimming.
MOUNT BOLTS
Replace. 6 x 1 . Om m
DOWELPIN 11 N.m 11.1 kgf.m, I lbt.ft)
6x1.0mm (cont'd)
1 1 N , m 1 1. 1 kgt.ni, O-RING Apply liquidgasketto
8 tbr.ftl Replace. the bolt threads.

7-3
lllustrated Index
(cont'dl
rubricatealt internalpartswith engineoil duringreassembly.
I
NOTE:
. Apply liquidgaskettothe matingsurfacesofthe right sidecoverand oil pump casebeforeinstallingthem.
! Use liquidgasket,pan No. 08718- 0001or 08718- 0003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit.
OII.PAN
D16Y5.Dl6Y8 engin"", WASHER Apply liquid gaskerto Relerto page7-23
DnAtNBoL,
39 N.m 14.0kgf'm, these potnts, wheninstalling.
29 tbf.f!) FLYWHEELCOVER
\ IM/T)
\
\,-,
12 x 1.0mm
6r1.omm \% 1 1 8N . m
12 N.m (1.2kgf'm, (12.O kst.m, 87 lbl.ftl
8.7 lbf.trl

1 1 x 1 . 5m m
51 N.m
\s
15.2kgt m, 38 lbf.{t)
Applyengineoilto the bolt FLYWHEELIM/TI
threads.
NOTE:Aftertorquing
each cap, turn crankshaft OIL PAN GASKET
to checklor binding. Replace.

DRIVEPLATECOVER
MAIN
BEARING
lA/T or CVTI

1 2 x 1 . Om m
MAIN BEARINGS 74 N.m
Selection,page7-8 (7.5 kgf.m, 54 lbf.ft)
NOTE:New main bearingsmust
be selectedby matching crank
DRIVEPLAYE(A/T or CVTI
Checkfor cracks.
6 x 1.0 mm
1 1 N . m 1 1 . 1k g t . m ,
8 tbf.frl
6 x 1.0 mrn
1 1 N . m { 1 . 1 k g t . m ,8 l b f . f r l CRANKSHAFTOIL SEAL

pages7-19and 7-25
OIL SCREEN Replace.

GASKET RIGHT SIDE COVER

Replace. Apply liquidgasket
OIL PUMP to mating surface.
Overhaul,page I 9
Removal/lnspection, DOWEL PIN
page 8-10
Apply liquidgasket
to mating surface. THRUSTWASHERS
Groovedsidesface outward.
NOTE:Thrust washerthickness
is fixed and must not be changed
by grindingor shimming.

CRANKSHAFT SEAL DOWEL PIN BREATHINGPORT COVER

Installation,pages7-24 MOUNT BOLTS
a n d8 - 1 1 6 x 1.0mm \
Feplace. 11 N.m {1.1 kgf.m, 8 lbf.frl
'1 Apply liquidgasketto
6 x .0 mm
' 1 1N . m 1 1. 1 k g f . m , the bolt threads.
I lbt.fr)

7-4
NOTE:New rod bearingsmust be selectedby matchingconneclingrod assemblyand crankshaftidentificationmarkings
(seepage7-9).

PISTONINSTALLATIONDIRECTION:
Lubricate all internal parts with engine oil during
reassemblv. EXHAUST

4\A6\/A
l o o l t . - l . t l
v\y\7v
INTAKE

tl,^t , PISTONRINGS

w,
*al pase7-18
olisnment,
@ )
PISTONPIN
Removal,page7-14 PISTON
page7-15
Installation, page7-12
Inspection,
hspection,page7-16 NOTE: Belore removing piston, inspectthe
top of the cylinderborefor carbonbuild,upor
ridge. Removeridge il necessary,page 7-'10

CONNECTING ROD
End play, page7-6 ENGINEBLOCK
S e l e c t i o n ,p a g e 7 - 1 5 page7-13
Cylinderboreinspection,
page7-'13
Warpageinspection,
Cylinderborehoning,page7'14

CONNECNNGROD
BEARINGS
Clearance.page 7-8
Selection,page 7-9

Inspecttop of each cylinder bore

for c6rbonbuild-upor ridge
before removing piston.
Removeridge if necessary,page7-'10

CONNECNNGRODCAPNUT
CONNECTING ROOBEARING 8 x 0,75mm
page7-20
lnstallation. 3 1N m ( 3 , 2 k g f . m ,
NOTE: Installcaps so the 23 tbt.ft)
bearing recessis on the Applyengineoil to
same side as the recess the bolt threads.
in the rod. NOTE: After torquing each bearing
cap, rotatecrankshaftto
checktor binding.

7-5
 GonnectingRod and
Flywheel and Drive Plate Crankshaft
Replacement EndPlay
Manual Transmission: Conn€GtingRod End Play:
Removethe six flywheel bolts, then separatethe fly- Standard(New):0.15- 0.30mm {0.006- 0.012inl
w h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n , ServiceLimit: 0.,[|)mm {0.016inl
tightenthe bolts in a crisscrosspattern.

Htr
RINGGEARHOLDER--4T-1
07LAB- PV00100

ENGINEBLOCK
RINGGEAR
Inspectring gear 12 x 1.0mm
teeth for wear or 118 N,m 112.0kgtm,87 lbl.ftl
damage.
I

I
. ll out-of-tolerance,installa new connectingrod.
. lf still out-of-tolerance.replacethe crankshaft(see
pages7-9 and 7-20).

Pushthe crankshaftfirmly away from the disl indicator,

and zerothe dial againstthe end of the crankshaft.
Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimit.

RINGGEARHOLDER
07LAB- PV(x'l00

Automatic Transmission:
Removethe six drive plate bolts,then separatethe drive
platefrom the crankshaftflange.After installation,
tight-
en the bolts in a crisscrossoattern.

CrankshaftEnd Play:
Stsndard {N€w): 0.10- 0.35 mm {0.004- 0.0lit in}
ServicELimit: 0.45 mm (0.018inl

. lf end play is excessive,inspectthe thrust wsshers

and thrustsurfaceon the crankshaft.
Replacepans as necessary.

NOTE:Thrustwasherthicknessis fixed and must not be

changedeitherby grindingor shimming.
Thrust washersare installedwith groovedsidesfacing
outward.
1 2x 1 . 0m m
74 N.m {7.5kgf m,54lblftl

7 -6
Main Bearings
Clearance
1. T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves.

C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l t w i t h a
cleanshop towel.

Piaceone strip of plastigageacrosseach main jour-

nal.

NOTE:tt the engineis still in the car when you bolt

the main cap down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plasti-
gage further than just the torque on the cap bolt,
and give you an incorrectreading.For an accurate
r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e
c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r i n ga t a
lf the plastigagemeasurestoo wide or too narrow,
time.
(removethe engineif it's still in the carl. removethe
crankshaft,and removethe upper half ol the bear-
R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
ing. Installa new, completebearingwith the same
bolts.
color code (selectthe color as shown on the next
page),and recheckthe clearance.
lst step: 25 N.m 12.5kgf'm, 18 lbf'ft)
Final step: 51 N'm 15.2kgl.m, 38 lbf'ft)
CAUTION: Do not file, shim, or sqape the bearings
or the caps to adiust clearance.
NOTE:Do not rotatethe crankshaftduring inspec-
tton.
7. It the plastigageshows the clearanceis still incor-
rect,try the next largeror smallerbearing(thecolor
Removethe cap and bearing again. and measure
listedaboveor belowthat one),and checkagain.
the widest pad of the Plastigage.
NOTE: lf the oroper clearancecannot be obtained
Main Bearing-to-JournalOil Clearance:
by usingthe appropriatelargeror smallerbearings'
Standard lNew):
replacethe crankshaftand startover.
No. 1,5 Journals:
0.018- 0.036mm (0.0007- 0'001,+inl
No- 2, 3, i[ Jou]nals:
0.02/t- 0.0,[2mm {0.0009- 0.0017in)
Ssrvice Limit: 0-05 mm {0.002inl
Main Bearings ConnectingRod Bearings
Selection Clearance t
CAUTION: lf the codes are indeciDherablebecauseof an 1, Removethe connectingrod cap and bearinghalf.
accumulationot dirt and dust, do not scrub them with a
wire brush or scraper.Clean them only with solvent or 2. C l e a nt h e c r a n k s h a frto d j o u r n a la n d b e a r i n gh a l f
detergent. with a cleanshop towel.

CrankshaftBore Code Location 3. Placea strip of plastigageacrossthe rod journal.

Lettershave beenstampedon the end of the blockas a 4. R e i n s t a lt lh e b e a r i n gh a l f a n d c a p ,a n d t o r q u et h e

codefor the sizeof eachof the 5 mainjournalbores. nuts.
Use them, and the numbersstamDedon the crankshaft
(codesfor main journalsizel,to choosethe correctbear- Torque
inos. 31 N.m (3.2 kgf.m. 23 lbf.ftl

NOTE:Do not rotatethe crankshaftduring inspec-

tton. I
Removethe rod cap and bearinghalf,and measure
the widestpart of the plastigage.

Conn€ctingRod Eearing-to-JouJnalOil Clearance:

StandardlNewl: 0.020- 0.038mm
(0.0008- 0.0015in)
ServiceLimit: 0.05 mm (0.(X)2in)

I
Main Joulnal Code Location(Numbers)
I

PLASTIGAGESTRIP

lf the plastigagemeasurestoo wide or too narrow,

removethe upper half of the bearing,installa new,
completebearingwith the same color code (select
the color as shown on the next page),and recheck
Bearing ldentification the clearance.
Colorcodeis crankoore
on the
edge of CAUTION:Do not lile, shim. or scrapethe boarings
the bearing.
B c D or the caps to adiust clearance.
Smallerbearing{thicker)
7. lf the plastigageshows the clearanceis still incor-
Il l f-i--l I Red Pink
rect,try the next largeror smallerbearing(the color
G.een
--Jl l i s t e da b o v e o r b e l o wt h a t o n e ) ,a n d c h e c kc l e a r -
tt l t. .3 - lt l Green
Gr€en Brown
Black
a n c ea g a i n .

+ tn t + Green Brown Elack Blue NOTE; lf the prooer clearancecannot be obtained

Smaller Smaller by usingthe appropriatelargeror smallerbearings,
main bearing replacethe crankshaftand stan over. \
journ8l (thicker)

7-8
 Pistonsand
Crankshaft
Selection Removal
CAUTION:lf the codes are indecipherablebecauseof 1. Removethe oil pan assembly.
an accumulationol dirt and dust, do not scrub them
with a wire brush or scraper,Clean them only with sol- Removethe right sidecover.
vgnt or detorgent.

ConnectingRod Code Location

Numbershave been stampedon the side of each con-

necting rod as a code for the size of the big end. Use RIGHT SIDE
COVER
them, and the lettersstampedon the crankshaft(codes
for rod journalsize),to choosethe correctbearlngs.

Halfof the numberis

stampedon bearing
capand the other
hall is stampedon the
rod.

connecting Rod Journal code Locations lLettersl

OIL SCREEN

B€aring ldentif ication

Colorcodeis on the Larger big end bore
edge of
the bearing. 2 3 4

Smallerbearing{thicker)

I F;.'l I Red Pink Green

Erown
O-RING
RePlace
l l B o r l l l l Pink Green
ll .-.------.ll
I I Corlll | | Green Brown Black
l - l
Blue Remove the oil pump.
I l D o , r lr+r r
Gr€en Brown Black 4.

Smaller Smaller
rod bearing
iournal (thicker)

7-9
Pistonsand Crankshaft
Removal(cont'dl
5. Removethe boltsand the bearingcap. Removethe upper bearing halvesfrom the connect-
ing rods and set them asidewith their respectivecaps.
CAUTION: To prev6nt warpago, unscrew the bohs
in soquencel/3 turn at a tims; rgpoat the sequenco Reinstallthe main capsand bearingson the engine
until 8ll bolts ara loosonsd. In properorder.

MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE '10. you

lf canfeela ridgeof metalor hardcarbonaround
t h e t o p o f e a c h c y l i n d e r ,r e m o v e i t w i t h a r i d g e
reamer.Follow the reamer manufacturer'sinstruc-
tions.

CAUTION: lf the ridgo is not removed, it may dam-

age tho plstons as they are pushed out.

Removethe rod caps/bearings and main caps/bear-

ings.Keepall caps/bearings
in order 't1.
Use the wooden handle of a hammer to drive the
pistonsout.
7. Lift the crankshaftout of the engine,being careful
not to damagejournals.

12. Reinstallthe connectingrod bearingsand capsafter

removingeachpiston/connecting rod assembly.

CRANKSHAFT 1 3 . Mark each piston/connecting

rod assemblywith its
cylindernumberto avoid mixup on reassembly.

NOTE:The existingnumber on the connectingrod

does not indicateits position in the engine,it indi- \
catesthe rod bore size.

7-10
Grankshaft
Inspection
. Cleanthe crankshaftoil passageswith pipe cleaners Out-of-Roundand Tapel
or a suitablebrush.
. Measureout-o{-roundat the middle of each rod
. Checkthe keywav and threads. and main journalin two places.

Alignmont . The differencebetweenmeasurementson each

journalmust not be more than the servicelimit,
. M e a s u r er u n o u t o n a l l m a i n i o u r n a l st o m a k e
surethe crankis not bent. Journal Out-ot-Round:
Standard (Now): 0.0025mm (0.0001inl max.
. The differencebetweenmeasurementson each ServiceLimit: 0.005mm (0.0002inl
journalmust not be more than the servicelimit.

CrankshaftTotal IndicatadRunout:
Standard {Nowl: 0.03 mm 10.001in} max.
SorviceLimh: 0.04 mm 10.002in)

DIAL INOICATOR
Rotate lwo complete round at middle.
revolutions.

MeasurelaPer
at edges.

Suppon with lathe

lype tool or V-blocks.

. Measuretaper at edges of each rod and main

journal.

. The differencebetlveenmeasurementson each

journalmust not be more than the servicelimit.

JournalTaper:
Standard{Newl:0.0025mm (0.0001in) max.
ServiceLimit: 0.005mm 10.0002in)

7-11
Pistons
Inspection
1. Checkthe pistonfor distortionor cracks. 3. Calculatethe difference between the cvlinder bore
diameter(seepage7-131and pistondiameter.
NOTE:lf cylinderis bored,an oversizedpistonmust
be used. Piston-to-Cylind€rClearanca
Standsrd {New): 0.010- 0.0i|()mm
2. M e a s u r ep i s t o n d i a m e t e ra t d i s t a n c eA t r o m t h e (0.000'l- 0.0016inl
bottom of the skirt. ServiceLimit: 0.05 mm {0.002inl

A: 5 mm (0.2in)

Piston Diameter:
Standard (N€w): 74.990- 74.990mm
12.9520- 2.952itinl
ServiceLimh: 7i1.970mm {2.9516in}

SKIRTDIAMETER

lf the clearanceis near or exceedsthe servicelimit,

inspectthe piston and cvlinderblock for excessive
wear.

Oversiz€Piston Dismatel
0.25175.23-75.21mn (2.9618- 2.9622inl
0.50:75.48- 75.49mm 12.9716- 2.9720in)

7-12
 Cylinder Block
Inspection
'1. Measure .
wear and taDerin directionsX and Y at th ree lf measurementsin any cylinderare beyondthe
levelsin eachcvlinderas shown. OversizeBoreServiceLimit,replacethe block.

. lf the block is to be rebored.refer to PistonClear-

anceInspection (seepage7 12)afterreboring.

NOTE;Scoredor scratchedcylinderbores must be

honed.

ReboringLimit: 0.50 mm (0.020in)

2. Checkthe top of the blockfor warpage.

Measurealong the edgesand acrossthe centeras
shown.

SURFACES
TO 8E MEASURED

Cylinder Bore Size

Standard {New): 75.00- 75.02mm
(2.953- 2.95,1in)
S€rvicoLimit: 75.07mm {2.955inl Engine Block Warpage:
Standard(New):0.07mm (0.003in) max.
OvsFize ServiceLimit: 0.10 mm 10.004in)
O.25t75.25- 75.27mm (2.9626- 2.963,[in]
0.50:75.50- 75.52mm 12.9721-2.9732in1
PRECISION
STRAIGHTEDGE
Bore Taper
Limit (Differencebetwoen tirst and third measure.
m6nt) 0.05 mm (0.002in)

7-13
).
GylinderBlock Piston Pins
BoreHoning Removal
l. Measurecylinderboresas shownon page7-13.lf the 1. Assemble the specialtool as shown.
blockis to be reused,honethe cylindersand remea-
surethe bores. PISTONBASEHEAD
07973- SB00100
Honecylinderboreswith honing oil and a fine (400 f t
grit) stonein a 60 dagreecross-hatch
pattern.
PISTONPIN BASE
NOTEi INSERT
. Use only a rigid hone with 400 grit or tiner stone 07973- PE00a00
such as Sunnen,Ammco,or equivalent.
. Do not usestonesthat are worn or broken.

g
E.
g\
Y .,rro")". rr*,"o
079?3- 6570600
W h e n h o n i n g i s c o m p l e t e .t h o r o u g h l yc l e a n t h e
engine block of all metal particles.Wash the cylin-
der bores with hot soapy water, then dry and oil 2. Assembleand adjust the length of the piston p t n
immediatelyto preventrusting. driverand shaftto 53 mm (2.1in) as shown.
PISTON PINDRIVER
HEAD
NOTE:Neverusesolvent,it will only redistribute
the 07973- PE00320
grit on the cylinderwalls. Pres3

lf scoring or scratchesare still presentin cylinder

bores after honing to the service limit. rebore the
+ 53 mm(21 in)

cylinderblock,

NOTE:Some light verticalscoringand scratchingis PISTONPIN

acceptableif it is not deep enoughto catchyour fin- DRIVERSHAFT
0?973- PE00310
gernailand does not run the full lengthof the bore.
PILOTOOLLAR
CYLINDERBLOCK 07973- PE00200

CYLINDERHONE

NOTE|Usea hydraulicpress.
When pressingthe pin in or out,
makesure that the recessed
NOTE: ponionofthe pistonaligns
. After honing,cleanthe cylinderthoroughlywith with the lips on the collar.
soapy waler.
. Only a scoredor scratchedcylinderbore must be Placethe piston on the specialtool and press the
noned. pin out with the specialtoolsand a hydraulicpress.

7-14
 GonnectingRods PistonPins
Seleetion Installation
Eachrod falls into one of four toleranceranges(from 0 to 1. Usea hvdraulicDressfor installation.
+ 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in)
incrementsldependingon the sizeof its big end bore.lt's a When pressingthe pin in or out, be sure you posi-
then stampedwith a number 11,2, 3, or 4l indicatingthe tion the rscessedflat on the piston againstthe lugs
ran9e. on the baseattachment,
Y o u m a y l i n d a n y c o m b i n a t i o no l 1 , 2 , 3 , o r 4 i n a n y
engine.
The arrow must face the
timing belt side ol the
Normal Bore Size: ,18.0mm (1.89inl engineand the connecting
rod oil hole must face the
NOTE: rear of the
ReferencenumbeG are for big end bore sizeand do
NOTindicatothe positionof the rod in the engine,
Inspectconnectingrod for cracksand heatdamage.

PISTOI{P|r{DRIVERHEAD
07973- PEOO320

Adjust the length of the

piston pin driver to
53 mm (2.09in)

PISTO PII{ DRIVERSHAFT

07973-PE00310

PFroI{Prr{
ffi--Z PILOTCOTLAR
07973- PEq)200

PISTOI{PINBASE I SERT
07973 - PCOO400

PISTOI{BASEHEAD
07973 - SB(xtl (xt

7-15
)
PistonPins
Inspection \ {
'1. Measurethe diameterot the pistonpin. 3. Measurethe pistonpin-to-piston
clearance.

Piston Pin Diamcter: NOTE:Checkthe pistonfor distortionor cracks.

Standard (New): 18.994- 19.000mm
(0.7,078- 0.7{80 inl lf the piston pin clearanceis greaterthan 0.024mm
OveIsiz€: 18.997- 19.003 ( 0 . 0 0 0 9i n ) , r e m e a s u r eu s i n g a n o v e r s i z e dp i s t o n
{0.7,u9 - 0.7,181in) pin.

pistonpins are oversize.

NOTE:All replacement Piston Pin-to-PistonClsarance:
Standard {Newl: 0.010- 0.022mm
{0.0004- 0.0009inl

Checkthe differencebetweenthe pistonpin diame-

ter and the connectingrod smallend diameter,
2. Zerothe dial indicatorto the pistonpin diameter.
Piston Pin-to-ConnectingRod Int€rferonc€:
Standard (New): 0.014- 0.040mm
10.0006- 0.0016inl

7-16
PistonRings
EndGap Replacement
1 . Using a piston, push a new ring into the cylinder 1 . Usinga ring expander,removethe old pistonrings.
bore 15- 20 mm (0.6- 0.8 in) trom the bottom.
2. Cleanall ring groovesthoroughly.
Measurethe pistonring end-gapwith a feelergauge:
NOTE:
. lf the gap is too small,checkto see if you have . U s e a s q u a r e d ' o f fb r o k e nr i n g o r r i n g g r o o v e
the properringsfor your engine. cleanerwith bladeto fit pistongrooves.
. lf the gap is too large,recheckthe cylinderbore . Top ring grooveis 1.0mm (0.039in) wide.
diameteragainstthe wear limits on page7-13. . Secondring grooveis 1.2mm (0.047in) wide.
lf the bore is over the servicelimit. the cvlinder . O i l r i n gg r o o v ei s 2 . 8m m ( 0 . 1 Ii n )w i d e .
blockmust be rebored. . Filedown the bladeif necessary.

Piston Ring End-Gap: CAUTION:Do not uso a wire brush to clean ring
Top Ring lands, or cut ring lands doeperwith cleaningtool.
St8ndardlNswl: 0.15- 0.30mm
{0.006- 0.012in) NOTE:lf the pistonis to be separatedfrom the con-
ServiceLimit: 0.60 mm 10.024inl nectingrod, do not installnew ringsyet.

SecondRing Installnew rings in the proper sequenceand posi-

Standard lN6wl: 0.30- 0.,l5mm tion {seepage7-18).
{0.012- 0.018inl
ServiceLimit: 0.70 mm (0.028inl NOTE:Do not reuseold pistonrings.

Oil Ring RINGEXPANDER

Standard lNewl: 0.20- 0.70 mm {Commercially
available)
{0.008- 0.028inl
SorviceLimit: 0.80 mm (0.031in)

15-20 mm
{0.6 -O.8 inl

7-17
PistonRings
Clearance
Ring-to-Groove Alignment
After installinga new set of rings, measurethe ring-to- 1, Installthe ringsas shown.
grooveclearances:

Top Ring Clearance

TOPBINGlchromo)
Standard lNew): 0.035- 0.060mm
{0.0014- 0.0024in}
Servic. Limit: 0.13 mm (0.005inl

SecondRing Clearance
Standard (Now): 0.030- 0.055mm
(0.0012- 0.0022io)
ServiceLimit: 0.13 mm 10.005inl

Piston Ring Dimensions:

r-T- f
I l r '
I I '
| . - !
A

Top Ring (Standatd):

A: 2.6 mm {0.10in}
B: 1.0mm (0.0/tin)

Second Ring {Standard):

A: 3.0 mm (0.12inl
B: 1.2mm (0.05inl

NOTE: The manufacturingmarks must be facing

upward.

,orrrno--"-@
SECONORING.>

7-18
 CrankshaftOil Seal
lnstallation
2. Rotatethe rings in their groovesto make sure they The sealsurfaceon the blockshouldbe dry.
do not bind. Apply a light coatof oil to the crankshaftand to
the lio of the seal.
Positionthe ring end gaps as shown
1. Drivethe crankshaftoil seal into the right side cover
usingthe specialtools.
DO NOTpositionany rrnggap
SECONDRINGGAP at pistonthrustsurfaces, NOTE:Drivethe crankshaftoil sealin squarely.

DRIVER
07749- 0010000

Approx. 90"

TOP RINGGAP

DO NOTpositionsny ring gaP

in linewith the pistonpin hole. OIL RINGGAP

Installseal with the

part numberside
facing oui.

Confirmequal clearanceall the way around with a

feelergauge.

0.5- 0.8 mm {0.02- 0.03inl

Clearance:

0 . 5- 0 . 8 m m
10.02-O.03in)

NOTE:Referto pages'I-24and 8-11for installation

of the oil oumo sidecrankshaftoil seal.

7-19
I
Pistons Crankshaft
lnstallation lnstallation
\ {
Beforeinstallingthe pistons,applya coat of Betoreinstallingthe crankshaft,
apply a coatot
engineoil to the ring groovesand cylinder engineoil to the main bearingsand rod bear-
bores. ings,

1. lf the crankshaft is already installed: 1. Installthe thrust washersin the No. 4 journal of the
. Set the crankshaftto BDCfor each cylinder. cylinderblock.
. Removethe connectingrod caps.and slip short
sectionsof rubber hose over the threadedends Insertbearinghalvesin the cylinderblockand con-
of the connectingrod bolts. nectingrods.
. Installthe ring compressor,checkthat the bear
ing is securelyin place,then positionthe piston Holdthe crankshaftso the rod journalsfor cylinders
i n t h e c y l i n d e r a. n d t a p i t i s u s i n gt h e w o o d e n No. 2 and No.3 are straightdown.
h a n d l eo f a h a m m e r .
. Stop after the ring compressorpops free, and Lowerthe crankshaftinto the block,seatingthe rod
checkthe connectingrod-to-crank journal align- j o u r n a l si n t o c o n n e c t i n gr o d s N o , 2 , N o . 3 . I n s t a l l
ment beforepushingthe pistoninto place. the rod capsand nutsfinger-tight.
. Installthe rod capswith bearings,and torquethe
nutsto:
31 N.m 13.2ksl.m,23 lbf.ti)
Apply engineoil to the bolt threads.

2. lf the crankshaftis not installed: -

. R e m o v et h e r o d c a p s a n d b e a r i n g s i,n s t a l lt h e l- rrn
---1l
-'--tllf -l
)- t--l
ring compressor,then positionthe piston in the
cylinderand tap it in usingthe woodenhandleof ltll
a hammer. THRUST WASHERS
. Positionall Distonsat top deadcenter.
The arrow must face
Groovedsidestace
L {
the timing belt side
of the engjne. Rotatethe crankshaftclockwise.seat journals into
connectingrods No. 1 and No.4. lnstallthe rod caps
and nutsfinger-tight.

NOTE:Installthe caps so the bearingrecessis on

the sameside as the recessin the rod.

Check rod bearing clearancewith plastigage(see

page7-8).then torquethe capnuts.

RUBEER Torque:
NOTE:Maintaindownwardforce on the ring com- 31 N.m (3.2 kgf.m,23 lbf,ft)
p r e s s o rt o p r e v e n tr i n g s f r o m e x p a n d i n gb e f o r e Apply engineoil to the bolt threads.
enteringthe cylinderbore.
RING NOTE: Referencenumbers on the connectingrod
COMPRESSOR
(Commercially
available)
are for big-endbore toleranceand do not indicate
the positionof the pistonin the engine.

\'
Lineup the markswhen
installingthe connectingrod d
cap.

7-20
7. Installthemain bearingcaps. 8. Apply liquid gasketto the block mating surfaceof
Checkclearanceswith plastigage(see page 7-7), the right side cover, then install it on the cylinder
then tightenthe bearingcap bolts in 2 steps. block.

Fi6t st6p: 25 N'm (2.5 kgf'm. 18 lbt.ft) NOTE:

Secondstsp: 5t N.m (5.2 kgf.m, 38 lbf,ft) . Use liquidgasket,part No. 08718- 0001or 08718
- 0003.
NOTE: Coat the thrust washer surfacesand bolt . Checkthat the matingsurfacesare cleanand dry
thresdswith oil. beforeapplyingliquidgasket
. Apply liquidgasketevenly,b6ingcarefultocover
MAN BEAHNG CAP BOLTSTIGHTENINGSEOUENCE allthe matingsurface.
. To preventoil leakage.apply liquidgasketto the
innerthreadsof the bolt holes.
. Do not install the parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket,
Insteadreapplyliquid gasketafter removingthe
old residue,
. After assemblv,wait at least 30 minutes before
fillingthe enginewith oil.

RIGHTSIDECOVEB

CAUTION: Whenever any crankshaft bearing or

connecting rod bgajing is rgplacad, it is neces3ary
aft6r roassemblyto run the ongino at idling spood
until it reachesnormal operating temperalure, thon
continuo to run it for approximalely 15 minutes.

6 x 1.0mm
1 1 N . m { 1 . 1kgl.m,
8 tbt.ftl
DOWEL PIN

(cont'd)

7-21
Crankshaft O i l Pa n
Installation(cont'd) Installation
9. Apply liquid gasketto the oil pump mating surface O16Y7enginc:
o f t h e b l o c k t, h e n i n s t a ltl h e o i l p u m p o n t h e c y l i n -
der block. 1. Apply liquid gasketon the oil pump and right side
covermatingareasas shown below.
Apply greaseto the lipsof the oil seals.
T h e n ,i n s t a l tl h e o i l p u m p w h i l e a l i g n i n gt h e i n n e r NOTE:
. hen the pump is in
r o t o r w i t h t h e c r a n k s h a f tW . Use liquidgasket,part No.08718- 0001or 08718
place,clean any excessgreaseoff the crankshaft, - 0003.
then checkthat the oil seallips are not distorted. . Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
. Apply liquid gasketas an even bead. centered
betweenthe edgesof the matingsurface.
. lo preventoil leakage,apply liquid gasketto the
innerthreadsof the bolt holes.
Apply laquidgasket . Do not installthe parts if five minutes or more
alongthe broken h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t .
Insteadreapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least30 minutes before
fillingthe enginewith oil.

CYLINOER
Br_ocK
Apply liquid gasket
OIL PUMP HOUSING to these pornts.

NOTE:
. Apply a light coat of oil to the crankshaftand to L
t h e l i po f t h es e a l .
. U s e n e w O - r i n g sa n d a p p l y o i l w h e n i n s t a l l i n g
them.

1 0 . I n s t a ltlh e o i l p u m pa n d o i l s c r e e n .
6 x 1.0mm
11 N.m {1.1kgf.m,
6x1.0mm a tbt.{t}
11 N.m {1.1kgf.m,
OII- SCREEN

Apply liquid gasket

to these pornts,
DOWEL PIN

DOWELPIN
6 x 1.0mm
11 N.m O-RING
{'l.1 kgl.m, 8 lbf,lt} Replace. {

.,
r -zz
,.t ,.i
2. I n s t a ltlh e o i l p a ng a s k eat n d o i l p a n . D16Y5,D16Y8engines:

NOTE: 1. I n s t a ltlh e o i l p a ng a s k eot n t h e o i l p a n .

. Usea new oil pan gasket.
. Installthe oil pan no morethan five minutesafter NOTE:
applyingliquidgasket. . Use liquidgasket,part No. 08718- 0001or 08718
, 0003.
OILPAN . Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
o A p p l y l i q u i dg a s k e ta s a n e v e n b e a d .c e n t e r e d
betweenthe edgesof the matingsurface.
. To preventoil leakageapply liquid gasketto the
Apply liquid innerthreadsof the bolt holes.
gasketto . Do not installthe parts if five minutesor more
these poants.
haveelapsedsinceapplyingthe liquidgasket.
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least 30 minutesbefore
filling the enginewith oil.

OIL PAN

PAN
GASKET
to thesepoints. Replace.

3. Tightenthe bolts and n u t sf i n g e rt i g h ta t s i x p o i n t s

as shown below.

OIL PAN
GASKET
Replace.

Tightenall boltsand nuts,startingfrom boltO, clock-

wise in threesteps.

NOTE:Excessive tighteningcan causedistonionof

oil pan gasketand oil leakage.

Torque:12 N.m (1.2kgl.m,8.7lbt.ft)

(cont'd)

7-23
Oil Pan Oil Seals
Installation(cont'd) Installation
2. Apply liquid gasketto the block mating surfaces, NOTE:
t h e n i n s t a l tl h e o i l p a n .A p p l y l i q u i dg a s k e t o t h e . Engineremovalis not required.
shadedareas. . The crankshaftoil sealhousingshouldbe dry.
Apply a light coat of greaseto the crankshaftand to
the lips of the seals.

1. Usingthe specialtool, drive in the timing pulley-end

sealuntilthe driverbottomsagainstthe oil pump.
When the seal is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.

OIL PAN

3. Tighten the nuts finger{ight at six points as shown

L
o a o
07947-SB00200
lnstallseal with the
part number side
facingout.

4. Tightenall boltsand nuts,startingfrom nut O, clock-

wise in threesteps.

NOTErExcessive tighteningcan causedistortionof

oil pan gasketand oil leakage.

Torque:12 N.m (1.2kgf'm,8.7lbl.ft)

t-z+
2. Measurethe flywheel-endsealthicknessand the oil
seal housingdepth.Usingthe specialtool. drive the
flywheel-endseal into the rear cover to the point
where the clearancebetweenthe boftom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.02-
0.03in) (seepage7-191.

NOTE:Align the hole in the driver attachmentwith

the pin on the crankshaft.

07749-0010000

DRIVERATTACHMENT
07948-S800101
lnstallseal waththe
part numberside
facing out.

7-25