Engine Mechanical: Other Isuzu Axiom I

SERVICE PRECAUTION

ENGINE CLEANLINESS AND CARE

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.

1. A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation.
2. Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order.
3. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.
4. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.
5. The six cylinders of this engine are identified by numbers; Right side cylinders 1, 3 and 5, Left side cylinders 2, 4 and 6, as counted from crankshaft pulley side to flywheel side.

CYLINDER BLOCK

The cylinder block is made of aluminum die-cast casting for 75° V-type six cylinders. It has a rear plate integrated structure and employs a deep skirt. The cylinder liner is cast and the liner inner diameter and crankshaft journal diameter are classified into grades. The crankshaft is supported by four bearings of which width is different between No. 2, No. 3 and No. 1, No. 4; the width of No. 3 bearing on the body side is different in order to support the thrust bearing. The bearing cap is made of nodular cast iron and each bearing cap uses four bolts and two side bolts.

CYLINDER HEAD

The cylinder head, made of aluminum alloy casting employs a pent-roof type combustion chamber with a spark plug in the center. The intake and exhaust valves are placed in V-type design. The ports are cross-flow type.

VALVE TRAIN

Intake and exhaust camshaft on both banks are driven with a camshaft drive gear by the timing belt. The valves are operated by the camshaft and the valve clearance is adjusted to select suitable thickness shim.

INTAKE MANIFOLD

The intake manifold system is composed of the aluminum cast common chamber and intake manifold attached with six fuel injectors.

EXHAUST MANIFOLD

The exhaust manifold is made of nodular cast iron.

PISTONS AND CONNECTING RODS

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two compression rings and one oil ring. The piston pin made of chromium steel is offset 1 mm toward the thrust side, and the thrust pressure of piston to the cylinder wall varies gradually as the piston travels. The connecting rods are made of forged steel. The connecting rod bearings are graded for correct size selection.

CRANKSHAFT AND BEARINGS

The crankshaft is made of Ductile cast-iron. Pins and journals are graded for correct size selection for their bearing.

ENGINE NOISY

Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically.

Scheme 117

ENGINE OIL PRESSURE CHECK

1. Check for dirt, gasoline or water in the engine oil. Check the viscosity of the oil. Change the oil if the viscosity is outside the specified standard. Refer to Maintenance.
2. Check the engine oil level. The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal operating temperature (About 80° C).
6. Measure the oil pressure. Oil pressure should be: 392-550 kPa (56.9-80.4 psi) at 3000 RPM.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

MALFUNCTION INDICATOR LAMP

The instrument panel "CHECK ENGINE" Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions.

Scheme 118

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Scheme 121

1. Disconnect battery ground cable.
2. Remove engine cover from the dowels on the common chamber.
3. Disconnect positive crankcase ventilation hose.
4. Remove ground cable fixing bolt on cylinder head cover.
5. Ignition coil connector and ignition coil. Disconnect the three connectors from the ignition coils. Remove harness bracket bolt on cylinder head cover. Remove fixing bolts on ignition coils.
6. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts, then the cylinder head cover.

Note. Where do you refer the tech in case of bolt removal difficulties.

Scheme 122

Scheme 123

Scheme 124

1. Install cylinder head cover. Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bearing cap on front and rear sides. The cylinder head cover must be installed with in 5 minutes after sealant application to prevent hardening of sealant. Tighten bolts to the specified torque. Torque: 9 N.m (78 lb in)
2. Install fuel injection harness bracket and tighten bolt to the specified torque. Torque: 9 N.m (78 lb in)
3. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque: 4 N.m (35 lb in) CAUTION: Ignition coil assembly #6 is different from ignition coil assembly from #1 to #5. Ignition coil assembly #6 is short type. So, note it when installing ignition coil assembly of #6.
4. Connect ground cable and tighten bolts to the specified torque. Torque: 9 N.m (78 lb in)
5. Install positive crankcase ventilation hose.
6. Install engine cover mating with the dowels.

Scheme 125

Scheme 126

1. Disconnect battery ground cable.
2. Remove engine cover from the dowel on the common chamber.
3. Disconnect ventilation hose from cylinder head cover.
4. Disconnect three ignition coil connectors from ignition coils and remove harness bracket bolts on cylinder head cover then remove ignition coil fixing bolts on ignition coils and remove ignition coils.
5. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head cover.

Scheme 127

1. Install cylinder head cover. Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207B or equivalent) bead (diameter 2-3 mm) at eight places of arched areas of camshaft bracket on front and rear sides. The cylinder head cover must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. Tighten bolts to the specified torque. Torque: 9 N.m (78 lb in)
2. Tighten fuel injector harness bracket bolts to specified torque then reconnect fuel injector harness connector. Torque: 7.8 N.m (69 lb in)
3. Connect ignition coil connector and tighten ignition coil fixing bolts to specified torque. Torque: 4 N.m (35 lb in)
4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.

Scheme 128

1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly. Disconnect vacuum booster hose from common chamber. Disconnect connector from manifold absolute pressure sensor, Ion sensing module, throttle position sensor, solenoid valve, electric vacuum sensing valve, and EGR valve. Disconnect vacuum hose on canister VSV and positive crankcase ventilation hose, fuel rail assembly with pressure control valve bracket. Remove ventilation hose from throttle valve and intake duct and remove water hose. Remove the four throttle body fixing bolts. Remove exhaust gas recirculation valve assembly fixing bolt and nut on common chamber and remove EGR valve assembly. Remove two bolts from common chamber rear side to remove fuel hose bracket. Remove common chamber four bolts and four nuts then remove the common chamber.

Scheme 129

Scheme 130

Scheme 131

1. Install common chamber and tighten bolts and nuts to the specified torque. Torque: Bolt: 25 N.m (18 lb ft) Nut: 25 N.m (18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified torque. Torque: 10 N.m (87 lb in)
3. Install exhaust gas recirculation valve assembly and tighten bolt and nut to the specified torque. Torque: 25 N.m (18 lb ft)
4. Install throttle body and tighten bolts to the specified torque. Torque: 10 N.m (89 lb in)
5. Install ventilating hose to throttle valve and intake duct.
6. Connect vacuum hoses on canister VSV and positive crankcase ventilation hose. Tighten bolts for fuel rail assembly with pressure control valve bracket. Torque: 25 N.m (18 lb ft)
7. Connect each connector.
8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as shown in the illustration.
10. Install air cleaner duct assembly.

Scheme 132

1. Disconnect battery ground cable.
2. Disconnect O 2 sensor connector.
3. Remove exhaust front pipe three stud nuts from exhaust side and two bolts from rear end of exhaust front pipe.
4. Remove exhaust manifold eight fixing nuts and remove exhaust manifold from the engine.

Scheme 133

1. Install exhaust manifold and tighten exhaust manifold fixing nuts to the specified torque with new nuts. Torque: 57 N.m (42 lb ft)
2. Install exhaust front pipe and tighten three stud nuts and two bolts to the specified torque. Torque: Stud nuts: 67 N.m (49 lb ft) Bolts: 43 N.m (32 lb ft)
3. Reconnect O 2 sensor connector.

Scheme 134

1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to «TORSION BAR»(ref-168343-S21794513562004110500000) .
3. Remove exhaust front pipe three stud nuts and two bolts then disconnect exhaust front pipe.
4. Remove exhaust manifold eight fixing nuts then the exhaust manifold.

Valve Spring

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Scheme 137

1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard: 44.6 mm (1.756 in) Limit: 43.6 mm (1.717 in)
2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit: 2 mm (0.079 in)
3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 in) Standard: 196 N (44 lb) Limit: Less than 181 N (41 lb)

Valve Guide

Scheme 138

1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard: 5.977 mm - 5.959 mm (0.2353 in - 0.2346 in) Limit: 5.90 mm (0.2323 in) Exhaust Standard: 5.952 mm - 5.970 mm (0.2343 in - 0.2350 in) Limit: 5.90 mm (0.2323 in)
2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set.

Inside Diameter of the Vale Guide

Inlet clearance

Standard: 0.023 mm - 0.056 mm (0.0009 in - 0.0002 in)

Limit: 0.20 mm (0.00787 in)

Exhaust clearance

Standard: 0.030 mm - 0.063 mm (0.0012 in - 0.0025 in)

Limit: 0.20 mm (0.00787 in)

Valve Guide Replacement

Scheme 139

Scheme 140

1. Using Valve guide replacer: J-42899, drive out the valve guide from the combustion chamber side.
2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 in) (Measured from the cylinder head upper face)
3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance.

Scheme 141

1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 in) Limit: 39.47 mm (1.5539 in) Exhaust Standard: 39.3 mm (1.5472 in) Limit: 39.45 mm (1.5531 in)
2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit.

Valve seat contact width

Standard: 1.1 mm (0.0433 in)

Limit: 1.7 mm (0.0669 in)

Scheme 142

Contact Surface Angle on Valve Seat on Valve

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set.

Valve contact surface angle: 45°

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Scheme 144

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90°
3. Apply abrasive compound to the valve seat insert surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.

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Scheme 146

1. Arc weld the rod at several points. Be careful not to damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink.
3. Strike the rod and pull it out.
4. Carefully clean the valve seat press-fit section on the cylinder head side.
5. Heat the press-fit section with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means.
6. Insert the press-fit section into the valve seat horizontally. Standard fitting interference: 0.14 mm - 0.09 mm (0.0055 in - 0.0035 in)
7. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression.
8. Lap the valve and the seat.

Scheme 147

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Scheme 150

1. install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side.
2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J-37281, drive in a new oil controller.
3. Install valve to valve guide. Before installing valve guide apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward.
5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to install the split collars.
6. Install tappet with shim.
7. Install camshaft assembly. Refer to «CAMSHAFT»(ref-194298-S10173687532005092700000) . Valve Clearance Adjustments NOTE: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite of maximum cam lift (1) as shown in illustration below.

Valve Clearance Standard Value (Cold)

Intake: 0.23 mm - 0.33 mm (0.0091 in - 0.0130 in)

Exhaust: 0.25 mm - 0.35 mm (0.0098 in - 0.0138 in)

Selection of Adjusting Shim

Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement- Standard value)

Based on the above formula, the best suited shim should be selected from 41 types of shim (differently thick at 0.02 mm (0.0008 in) intervals from 2.40 mm (0.0945 in) through 3.2 mm (0.1260 in) thick). Install the shim and check valve clearance.

Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing bearings (Scheme 155)below. Select and install the new crankshaft bearings, paying close attention to the cylinder block journal hole.

Scheme 151

Scheme 152

Scheme 153

1. Diameter size mark (1) and the crankshaft journal.
2. Diameter size mark (1). The diameter size marks are stamped on the No.1 crankshaft balancer as shown in the illustration. NOTE: Take care to ensure the bearings are positioned correctly.

Scheme 154

Scheme 155

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Scheme 164

1. Crankshaft (12) Install the main bearings to the cylinder block and the main bearing caps. Be sure that they are positioned correctly. Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the main bearing back faces. Carefully mount the crankshaft. Apply engine oil to the thrust washer. Assemble the thrust washer to the No.3 bearing journal. NOTE: The oil grooves must face the crankshaft.
2. Rear oil seal (10) Remove the oil from the cylinder block and the retainer mounting surface. Apply sealant (TB-1207B or equivalent) to the retainer mounting surface, following the pattern shown in the illustration. The retainer must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. Apply engine oil to the oil seal lip. Align the cylinder block dowel pin holes with the rear retainer dowel pins. Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer. Torque: 18 N.m (13 lb ft) NOTE: Be very careful not to disengage the oil seal garter spring during installation of the rear retainer. If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip and install the oil seal using J-39201 oil seal installer.
3. Flywheel (9) Thoroughly clean and remove the oil from the threads of crankshaft. Remove the oil from the crankshaft and flywheel mounting faces. Mount the flywheel on the crankshaft and then install the washer. Hold the crankshaft to prevent from rotating then install the bolts in the order shown to the specified torque. Torque: 54 N.m (40 lb ft) NOTE: Do not reuse the bolt and do not apply oil or thread lock to the bolt.
4. Piston and connecting rod assembly (8) Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned. Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks must be facing the front of the engine. Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps. Apply engine oil to the threads and seating faces of the nuts. Tighten the nuts. Torque: 54 N.m (40 lb ft) After tightening the cap nuts, check to see that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces.
5. Install oil gallery (7) and tighten the bolts in 2 steps, in the order shown. 1st step: 29 N.m (22 lb ft) 2nd step: 55°- 65°
6. Cylinder block side bolts (6) Tighten all the bolts to the specified torque in the order shown. Torque: 39 N.m (29 lb ft) NOTE: Do not apply engine oil to the crank case side bolts.
7. Install oil pump assembly (5). Refer to «OIL PUMP»(ref-194304-S30965662032005092700000) .
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts. Torque: 25 N.m (18 lb ft)
10. Install crankcase with oil pan (2). Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. Apply a correct width bead of sealant (TB- 1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead. The crankcase assembly must be installed within 5 minutes after sealant application. Tighten the bolts and nuts to the specified torque. Torque: 10 N.m (87 lb in)
11. Install cylinder head assembly. Refer to «CYLINDER HEAD»(ref-194298-S37972772472005092700000) .

Scheme 165

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Scheme 167

Scheme 168

1. Remove cylinder head assembly (1). Refer to «CYLINDER HEAD»(ref-194298-S37972772472005092700000) .
2. Remove cylinder head gasket (2).
3. Remove crankcase with oil pan (3). Refer to «OIL PAN AND CRANKCASE»(ref-194304-S08079399982005092700000) .
4. Remove oil pipe and O-ring (4).
5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod lower bearing (12).
8. Remove piston and connecting rod assembly (7). NOTE: Before removing piston and connecting rod assembly, measure thrust clearance. Remove any ridge or carbon build up from the top end of the cylinder.
9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order.
10. Remove the piston pin (9) using J-24086-C piston pin service set and piston support with a press. NOTE: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin.
11. Piston (10)
12. Connecting rod (11)

Pistons

Carefully clean away all the carbon adhering to the piston head and the piston ring grooves.

Note. Never use a wire brush to clean the pistons. Damage will result. Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced.

Piston Diameter

1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin.

Piston grading position (from piston head)

Piston grading position: 43.0 mm (1.6929 in)

Scheme 169

The size mark (1) for piston outside diameter is represented as shown in Figure.

Outside Diameter

Size Mark A: 93.360 mm - 93.370 mm (3.6756 in - 3.6760 in)

Size Mark B: 93.371 mm - 93.380 mm (3.6760 in - 3.6764 in)

Size Mark C: 93.381 mm - 93.390 mm (3.6764 in - 3.6768 in)

Scheme 170

Measure the cylinder bore inside diameter. Refer to CYLINDER BLOCK .

Scheme 171

Piston Rings

Any worn or damaged part discovered during engine overhaul must be replaced with a new one.

Scheme 172

Scheme 173

1. Ring end gap measurement Insert the piston ring into the bore. Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest. Measure the ring end gap. Compression Ring 1st ring Standard: 0.300 mm - 0.400 mm (0.0118 in - 0.0157 in) Limit: 1.0 mm (0.0394 in) 2nd ring Standard: 0.450 mm - 0.600 mm (0.0177 in - 0.0236 in) Limit: 1.2 mm (0.0472 in) Oil ring Standard: 0.150 mm - 0.450 mm (0.0059 in - 0.0177 in) Limit: 1.05 mm (0.0413 in) Positioning mark (1) is painted as shown in the illustration. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring
2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove / piston ring clearance exceeds the specified limit, the piston must be replaced.

Compression Ring Clearance

Standard: 0.025 mm - 0.065 mm (0.0006 in.-0.0015 in)

Limit: 0.1mm (0.0059 in)

Scheme 174

Piston Pin

Note. Do not reuse the old piston pin.

Scheme 175

1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions.
2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced. Standard: 0.023 mm - 0.038 mm (0.0009 in - 0.0015 in)
3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced.

Clearance

Standard: 0.010 mm - 0.017 mm (0.0004 in.-0.0007 in)

Limit: 0.040 mm (0.0016 in)

Scheme 176

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Scheme 179

1. Check the connecting rod alignment If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm: (3.937 in) Limit: 0.15 (0.0059) Twist per 100 mm: (3.937 in) Limit: 0.20 (0.0078)
2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod If the clearance exceeds the specified limit, the connecting rod must be replaced. Standard: 0.16 mm - 0.35 mm (0.0063 in. - 0.0138 in) Limit: 0.40 mm (0.0157 in)
3. Measure the oil clearance between the connecting rod and the crankshaft. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod caps in the cylinder number order. Clean the rod bearings and the crankshaft pins. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 N.m (40 lb ft) NOTE: Do not allow the crankshaft to rotate. Remove the rod caps. Measure the width of the plastigage and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard: 0.019 mm - 0.043 mm (0.0007 in - 0.0017 in) Limit: 0.08 mm (0.0031 in) Clean the plastigage from the bearings and the crankshaft pins.

Con-Rod Bearing Selection

Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1).

Note. Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure.

Scheme 180

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Scheme 184

1. Install connecting rod
2. Install piston
3. Install piston pin Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. NOTE: When changing piston / connecting rod combinations, do not change the piston / piston pin combination and do not reuse the old piston pin. Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side. With J-24086-C Piston pin service set and a press, press fit the piston pin. NOTE: Heat the connecting rod small end to a suitable temperature to ensure smooth installation.
4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring Install piston rings in the following sequence. Oil ring Expander ring Upper side rail Lower side rail 2nd compression ring 1st compression ring The compression rings must be set with the T or T2 mark facing up. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly.
5. Install piston and connecting rod assembly. Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. Tighten the connecting rod cap nuts Torque: 54 N.m (40 lb ft) NOTE: Do not apply engine oil to the bearing back faces.
6. Install oil gallery. Refer to «CRANKSHAFT AND MAIN BEARINGS»(ref-194298-S24583729812005092700000) .
7. Install oil strainer and O-ring.
8. Install oil pipe and O-ring.
9. Install crankcase with oil pan. Refer to «OIL PAN AND CRANKCASE»(ref-194304-S08079399982005092700000) .
10. Install cylinder head gasket.
11. Install cylinder head assembly. Refer to «CYLINDER HEAD»(ref-194298-S37972772472005092700000) .

Scheme 185

Flatness

1. Using a straight-edge and feeler gauge, check that the upper surface of the cylinder block is not warped. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the warpage exceeds the limit.

Scheme 186

Warpage

Limit: 0.15 mm (0.0059 in)

Maximum repairable limit: 0.15 mm (0.0059 in)

Cylinder Bore

Use a cylinder gauge to measure the cylinder bore diameter in both the axial and thrust directions. Each measurement should be made at six points.

Cylinder Bore Inside Diameter

Limit: 93.530 mm (3.6823 in)

If the measurement exceed the specified limit, the cylinder block must be replaced.

Diameter

Grade A: 93.400 mm - 93.410 mm (3.6772 in - 3.6776 in)

Grade B: 93.411 mm - 93.420 mm (3.6776 in - 3.6779 in)

Grade C: 93.421 mm - 93.430 mm (3.6780 in - 3.6783 in)

Scheme 187

Note. For information on piston diameter, please Refer to INSPECTION AND REPAIR of the Piston and Connecting Rod.

1. The "Grade" mark (1) is stamped at the position illustrated.

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Scheme 198

1. Install cylinder block.
2. Install crankshaft. Install the main bearings to the cylinder block and the main bearing caps. Be sure that they are positioned correctly. Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the bearing back faces. Carefully mount the crankshaft. Apply engine oil to the thrust washer. Assemble the thrust washer to the No. 3 bearing journal. NOTE: The oil grooves must face the crankshaft.
3. Install rear oil seal retainer. Remove oil on cylinder block and retainer fitting surface. Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration. The oil seal retainer must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. Tighten retainer fixing bolts to the specified torque. Torque: 25 N.m (18 lb ft)
4. Install flywheel Thoroughly clean and remove the oil from the threads of crankshaft. Remove the oil from the crankshaft and flywheel mounting faces. Mount the flywheel on the crankshaft and then install the washer. Holding the crankshaft stationary, tighten the flywheel bolts in the order shown. Torque: 54 N.m (40 lb ft) NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts.
5. Install piston and connecting rod assembly. Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. NOTE: Do not apply engine oil to the bearing back faces. Check to see that the piston ring end gaps are correctly positioned. Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks (1) must be facing the front of the engine.
6. Install oil gallery and tighten the bolts in 2 steps in the order shown. 1st step: 29 N.m (22 lb ft) 2nd step: 55°- 65°
7. Install cylinder block side bolts (1) and tighten crankcase bolts in sequence shown in the illustration. Torque: 39 N.m (29 lb ft)
8. Install oil pump assembly. Refer to «OIL PUMP»(ref-194304-S30965662032005092700000) .
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. Apply a correct width bead of sealant (TB- 1207C or its equivalent) to the contact surfaces of the crankcase. There must be no gaps in the bead. The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. Tighten the bolts and nuts to the specified torque. Torque: 10 N.m (87 lb in)
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to «CYLINDER HEAD»(ref-194298-S37972772472005092700000) .