Engine Mechanical (Service Information): Overhaul Scion tC II рестайлинг

REASSEMBLY [01/2014 - ]

1. INSTALL STIFFENING CRANKCASE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic-faced hammer, tap in 2 new ring pins until they stop. Standard protrusion height 4.3 to 5.3 mm (0.169 to 0.209 in.) TEXT IN ILLUSTRATION *1 Protrusion Height
2. INSTALL STIFFENING CRANKCASE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. TEXT IN ILLUSTRATION *A Front Side *B Lower Side Using an E5 and E8 "TORX" socket wrench, install the stud bolts. for stud bolt A Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for stud bolt B Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)
3. INSTALL ENGINE BALANCER ASSEMBLY Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned. TEXT IN ILLUSTRATION *1 Alignment Mark If the alignment marks are not aligned, realign them. Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place. TEXT IN ILLUSTRATION *1 Driven Gear *2 Damper Cover *3 Alignment Mark Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover. Install the engine balancer to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
4. INSTALL STIFFENING CRANKCASE ASSEMBLY Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration. TEXT IN ILLUSTRATION *1 Key Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Dimension Area Specified Condition Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick Application length A 28 mm (1.10 in.) TEXT IN ILLUSTRATION *1 Seal Packing *2 Continuous Line *3 Dashed Line Stiffening Crankcase Cylinder Block NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Do not apply oil for at least 4 hours after the installation. Do not start the engine for at least 4 hours after the installation. Check that the rear cutouts are as shown in the illustration. TEXT IN ILLUSTRATION *1 Cutout Clean the bolts and their installation holes. Apply adhesive to 3 threads or more at the end of bolt A. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Temporarily install the stiffening crankcase with the 11 bolts. Bolt Length Item Length Bolt A 65 mm (2.56 in.) Bolt B 35 mm (1.38 in.) Bolt C 125 mm (4.92 in.) Bolt D 165 mm (6.50 in.) HINT: Apply adhesive to bolt A before installing it Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase. for bolt A Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) except bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
5. INSTALL NO. 1 OIL PAN BAFFLE PLATE Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
6. INSTALL OIL STRAINER SUB-ASSEMBLY Apply a light coat of engine oil to a new gasket. TEXT IN ILLUSTRATION *1 Protrusion Align the protrusion of the gasket with the cutout of the oil strainer and install the gasket to the oil strainer. Install the oil strainer with the 3 bolts in several steps in the sequence shown in the illustration. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
7. INSTALL OIL PAN SUB-ASSEMBLY Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing. Do not apply oil for at least 4 hours after the installation. Do not start the engine for at least 4 hours after the installation. Install the oil pan with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Bolt A and nut A are tightened twice.
8. INSTALL OIL FILTER ELEMENT . Refer to «REPLACEMENT [05/2013 - ] - Step 4»(ref-615225-S38746355212014050900000)
9. INSTALL REAR ENGINE OIL SEAL See step 1
10. INSTALL CYLINDER BLOCK WATER JACKET SPACER Install the water jacket spacer to the cylinder block.
11. INSTALL CYLINDER HEAD GASKET See step 1
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 2
13. SET CAMSHAFT TIMING GEAR ASSEMBLY See step 4
14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing. Standard protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) TEXT IN ILLUSTRATION *1 Protrusion Height
15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing. Standard protrusion height 5.0 to 7.0 mm (0.197 to 0.276 in.) TEXT IN ILLUSTRATION *1 Protrusion Height
16. INSTALL CAMSHAFT HOUSING STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. Using an E8 "TORX" socket wrench, install the stud bolt. Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)
17. INSTALL NO. 1 CAMSHAFT BEARING Clean the No. 1 camshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper Install the camshaft bearing to the No. 1 camshaft bearing cap. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge. Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)
18. INSTALL NO. 2 CAMSHAFT BEARING Clean the No. 2 camshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper Install the camshaft bearing to the camshaft housing. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge. Standard distance 1.15 to 1.85 mm (0.0453 to 0.0728 in.)
19. INSTALL OIL CONTROL VALVE FILTER Install the oil control valve filter to the No. 1 camshaft bearing cap.
20. INSTALL CAMSHAFT See step 10
21. INSTALL CAMSHAFT BEARING CAP See step 11
22. INSTALL VALVE STEM CAP See step 3
23. INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 5
24. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY See step 6
25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY See step 12
26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY See step 13
27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY See step 14
28. INSTALL CRANKSHAFT TIMING SPROCKET Install the crankshaft timing sprocket to the crankshaft.
29. ADD ENGINE OIL See step 15
30. SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 16
31. INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 17
32. INSTALL CHAIN SUB-ASSEMBLY See step 18
33. INSTALL CHAIN TENSIONER SLIPPER See step 19
34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 20
35. INSTALL TIMING CHAIN GUIDE See step 21
36. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION See step 22
37. INSTALL TIMING CHAIN COVER PLATE Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
38. INSTALL TIMING CHAIN COVER TIGHT PLUG Using a 14 mm hexagon wrench, install a new gasket and plug. Torque: 30 N*m (306 kgf*cm, 20 ft.*lbf)
39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY . Refer to «INSTALLATION [01/2014 - ] - Step 1»(ref-615225-S06736415872014050900000)
40. INSTALL ENGINE MOUNTING BRACKET RH . Refer to «INSTALLATION [01/2014 - ] - Step 2»(ref-615225-S06736415872014050900000)
41. INSTALL TIMING CHAIN COVER OIL SEAL See step 1
42. INSTALL SPARK PLUG TUBE GASKET . Refer to «INSTALLATION [01/2014 - ] - Step 7»(ref-615225-S06736415872014050900000)
43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY . Refer to «INSTALLATION [01/2014 - ] - Step 8»(ref-615225-S06736415872014050900000)
44. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the crankshaft pulley. Using SST, hold the crankshaft pulley and install the pulley bolt. SST: 09213-54015 SST: 09330-00021 Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) HINT: Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)
45. INSTALL CRANKSHAFT POSITION SENSOR . Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S27052593842014050900000)
46. INSTALL WATER INLET HOUSING Install a new gasket and the water inlet housing with the 4 bolts and nut. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
47. INSTALL ENGINE WATER PUMP ASSEMBLY . Refer to «INSTALLATION [01/2014 - ] - Step 1»(ref-615227-S09792040022014050900000)
48. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY . Refer to «INSTALLATION [01/2014 - ] - Step 2»(ref-615227-S09792040022014050900000)
49. INSTALL THERMOSTAT . Refer to «INSTALLATION [01/2014 - ] - Step 1»(ref-615227-S41553270362014050900000)
50. INSTALL WATER INLET . Refer to «INSTALLATION [01/2014 - ] - Step 2»(ref-615227-S41553270362014050900000)
51. INSTALL NO. 1 WATER BY-PASS PIPE Install a new gasket and the water by-pass pipe with the 2 nuts and bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
52. INSTALL SEPARATOR CASE Apply a light coat of engine oil to a new gasket. Install the gasket to the separator case. Install the separator case with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
53. INSTALL PCV CASE Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Bolt A is tightened twice.
54. INSTALL PCV VALVE . Refer to «INSTALLATION [01/2014 - ] - Step 1»(ref-615251-S24663206812014050900000)
55. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side) . Refer to «INSTALLATION [05/2013 - ] - Step 2»(ref-615228-S05338824542014050900000)
56. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side) . Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S05338824542014050900000)
57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) . Refer to «INSTALLATION [05/2013 - ] - Step 2»(ref-615228-S04108428122014050900000)
58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) . Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S04108428122014050900000)
59. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new gasket to the oil filler cap. Install the oil filler cap to the cylinder head.
60. INSTALL SPARK PLUG . Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S42311741022014050900000)
61. INSTALL ENGINE COVER JOINT Install the 3 joints. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

REASSEMBLY [05/2013 - ]

HINT

Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION [05/2013 - ] .

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

1. INSTALL CYLINDER HEAD STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. Using an E7 "TORX" socket wrench, install the cylinder head stud bolts. Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)
2. INSTALL NO. 1 STRAIGHT SCREW PLUG NOTE: If coolant leaks from a straight screw plug or a plug is corroded, replace it. Using a 10 mm hexagon wrench, install 3 new gaskets and the 3 straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
3. INSTALL NO. 2 STRAIGHT SCREW PLUG NOTE: If coolant leaks from a straight screw plug or a plug is corroded, replace it. Using a 14 mm hexagon wrench, install a new gasket and the straight screw plug. Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
4. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
5. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new oil seals. TEXT IN ILLUSTRATION *A Intake Side *B Exhaust Side *1 Gray *2 Black *3 Mark "NOK" NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal onto the exhaust side or installing the exhaust oil seal onto the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. Using SST, push in the intake and exhaust valve oil seals. SST: 09201-41020 TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
6. INSTALL INTAKE VALVE Apply plenty of engine oil to the tip area of the intake valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the spring and install the retainer locks. SST: 09202-70020 09202-00010 Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
7. INSTALL EXHAUST VALVE Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the spring and install the retainer locks. SST: 09202-70020 09202-00010 Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.

Scheme 287

Scheme 288

Scheme 289

Scheme 290

1. REPAIR INTAKE VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the intake valve seat smooth. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Standard width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) TEXT IN ILLUSTRATION *1 Width Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.
2. REPAIR EXHAUST VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the exhaust valve seat smooth. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Standard width 1.2 to 1.6 mm (0.0472 to 0.0630 in.) TEXT IN ILLUSTRATION *1 Width Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.160 to 0.512 mm (0.00630 to 0.0202 in.) Maximum thrust clearance 0.512 mm (0.0202 in.) If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE Check the alignment marks on the connecting rod and cap to ensure correct reassembly. TEXT IN ILLUSTRATION *1 Alignment Mark Remove the 2 bolts and connecting rod cap. HINT: Keep the lower bearing and connecting rod cap together. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of Plastigage on the crank pin. TEXT IN ILLUSTRATION *1 Plastigage Install the connecting rod cap See step 11 . NOTE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap. HINT: Keep the lower bearing and connecting rod cap together. Measure the Plastigage at its widest point. Standard oil clearance 0.030 to 0.063 mm (0.00118 to 0.00248 in.) Maximum oil clearance 0.07 mm (0.00276 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 Number Mark NOTE: Remove the Plastigage completely after the measurement. If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number as that which is marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. Standard crank pin diameter 51.492 to 51.500 mm (2.0272 to 2.0276 in.) Standard Connecting Rod Big End Inside Diameter Item Specified Condition Mark 1 54.500 to 54.508 mm (2.1457 to 2.1460 in.) Mark 2 54.509 to 54.516 mm (2.1460 to 2.1463 in.) Mark 3 54.517 to 54.524 mm (2.1463 to 2.1466 in.) Standard Size Bearing Center Wall Thickness Item Specified Condition Mark 1 1.483 to 1.487 mm (0.0584 to 0.0585 in.) Mark 2 1.488 to 1.491 mm (0.0586 to 0.0587 in.) Mark 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) Perform the inspection above for each cylinder.
3. REMOVE PISTON WITH CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Remove the 8 bolts, 4 connecting rod caps and 4 lower bearings. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.
4. REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rods and connecting rod caps. HINT: Arrange the removed parts in the correct order.
5. INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Standard thrust washer thickness 1.93 to 1.98 mm (0.0760 to 0.0780 in.)
6. REMOVE CRANKSHAFT Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps from the cylinder block. HINT: Keep the No. 2 crankshaft bearings and crankshaft bearing caps together. Arrange the bearing caps in the correct order. Remove the crankshaft from the cylinder block. HINT: Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block. Check each crankshaft journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
7. REMOVE CRANKSHAFT THRUST WASHER Remove the thrust washers from the cylinder block.
8. REMOVE CRANKSHAFT BEARING Remove the crankshaft bearings from the cylinder block and bearing caps. HINT: Arrange the bearings in the correct order.
9. REMOVE CRANKSHAFT PULLEY KEY Using a screwdriver, remove the 2 pulley keys from the crankshaft.
10. REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. TEXT IN ILLUSTRATION *1 Piston Ring Expander Remove the oil ring and expander by hand. HINT: Arrange the removed parts in the correct order.
11. REMOVE PISTON PIN HOLE SNAP RING Insert a small screwdriver into the service hole and pry out the snap ring on the front side. NOTE: Do not remove the snap ring on the rear side unless it is necessary. When the snap ring heeds to be removed, be careful not to damage the piston.
12. REMOVE PISTON Gradually heat the piston up to 80 to 90°C (176 to 194°F). Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod. HINT: The piston and pin are a matched set. Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 2 bolts and 2 oil nozzles.
14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.
15. REMOVE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it.

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

1. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head gasket. Maximum warpage 0.05 mm (0.00197 in.) If the warpage is more than the maximum, replace the cylinder block.
2. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter 90.000 to 90.013 mm (3.543 to 3.544 in.) Maximum diameter 90.133 mm (3.549 in.) TEXT IN ILLUSTRATION *1 Thrust Direction *2 Axial Direction Front If the average diameter of the 4 positions is more than the maximum, replace the cylinder block.
3. INSPECT PISTON Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or a broken ring, clean the piston ring grooves. Using a brush and solvent, thoroughly clean the piston. NOTE: Do not use a wire brush. Using a micrometer, measure the piston diameter at a position that is 10.5 mm (0.413 in.) from the bottom of the piston (refer to the illustration). Standard piston diameter 89.970 to 89.996 mm (3.542 to 3.543 in.) If the diameter is less than the minimum, replace the piston with pin.
4. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust direction. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.004 to 0.043 mm (0.000157 to 0.00169 in.) Maximum oil clearance 0.10 mm (0.00394 in.) If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block.
5. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Standard Ring Groove Clearance Item Specified Condition No. 1 ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.) No. 2 ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.) Oil ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.) If the groove clearance is not as specified, replace the piston with pin.
6. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard End Gap Item Specified Condition No. 1 ring 0.22 to 0.27 mm (0.00866 to 0.0106 in.) No. 2 ring 0.37 to 0.42 mm (0.0146 to 0.0165 in.) Oil ring 0.10 to 0.20 mm (0.00394 to 0.00787 in.) Maximum End Gap Item Specified Condition No. 1 ring 0.87 mm (0.0342 in.) No. 2 ring 1.02 mm (0.0402 in.) Oil ring 0.80 mm (0.0315 in.) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block.
7. INSPECT PISTON PIN OIL CLEARANCE Check each mark on the piston, piston pin and connecting rod. TEXT IN ILLUSTRATION *1 Front Mark *2 Position Pin Hole Inside Diameter Mark *3 Connecting Rod Small End Bush Inside Diameter Mark - - HINT: The front mark is "2L" printed in raised letters. Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard Piston Pin Hole Inside Diameter Item Specified Condition Mark A 22.001 to 22.004 mm (0.86618 to 0.86630 in.) Mark B 22.005 to 22.007 mm (0.86634 to 0.86642 in.) Mark C 22.008 to 22.010 mm (0.86645 to 0.86653 in.) Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter Item Specified Condition Mark A 21.997 to 22.000 mm (0.86602 to 0.86614 in.) Mark B 22.001 to 22.003 mm (0.86617 to 0.86626 in.) Mark C 22.004 to 22.006 mm (0.86630 to 0.86638 in.) If the diameter is not as specified, replace the piston pin. Using a caliper gauge, measure the connecting rod small end bush inside diameter. Standard Connecting Rod Small End Bush Inside Diameter Item Specified Condition Mark A 22.005 to 22.008 mm (0.86634 to 0.86645 in.) Mark B 22.009 to 22.011 mm (0.86649 to 0.86657 in.) Mark C 22.012 to 22.014 mm (0.86661 to 0.86669 in.) If the diameter is not as specified, replace the connecting rod. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.013 mm (0.000512 in.) If the oil clearance is more than the maximum, replace the piston and piston pin as a set. Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement. Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance 0.017 mm (0.000669 in.) If the oil clearance is more than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
8. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a connecting rod aligner and feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the bend is more than the maximum, replace the connecting rod. Check for twist. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod.
9. INSPECT CRANKSHAFT Inspect for circle runout. Using a dial indicator and V-blocks, measure the circle runout. Maximum circle runout 0.003 mm (0.000118 in.) If the circle runout is more than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard main journal diameter 54.988 to 55.000 mm (2.1649 to 2.1654 in.) If the diameter is not as specified, check the crankshaft oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round are more than the maximum, replace the crankshaft. Inspect the crank pin. Using a micrometer, measure the diameter of each crank pin. Standard crank pin diameter 51.492 to 51.500 mm (2.027 to 2.028 in.) If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft. Inspect each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.003 mm (0.000118 in.) If the taper and out-of-round are more than the maximum, replace the crankshaft.
10. INSPECT CRANKSHAFT OIL CLEARANCE Install the crankshaft bearings See step 7 . Install the crankshaft thrust washers See step 8 . Clean each main journal and bearing. Place the crankshaft onto the cylinder block. Lay a strip of Plastigage across each journal. TEXT IN ILLUSTRATION *1 Plastigage Install the crankshaft bearing caps See step 9 . NOTE: Do not turn the crankshaft. Remove the crankshaft bearing caps See step 6 . Measure the Plastigage at its widest point. Standard oil clearance 0.016 to 0.039 mm (0.000630 to 0.00154 in.) Maximum oil clearance 0.05 mm (0.00197 in.) TEXT IN ILLUSTRATION *1 Plastigage NOTE: Remove the Plastigage completely after the measurement. If the oil clearance is more than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. TEXT IN ILLUSTRATION *1 Crankshaft Number Mark (B) *2 Cylinder Block Number Mark (A) *3 Diameter Mark *4 No. 1 *5 No. 2 *6 No. 3 *7 No. 4 *8 No. 5 EXAMPLE Cylinder block (A) "3" + Crankshaft (B) "4" = Total "7" Select the bearing marked "3". Bearing Chart (A) + (B) Bearing to be Used 0 to 2 1 3 to 5 2 6 to 8 3 9 to 11 4 Standard Cylinder Block Journal Inside Diameter (A) Item Specified Condition Mark 0 59.000 to 59.002 mm (2.32283 to 2.32291 in.) Mark 1 59.003 to 59.004 mm (2.32295 to 2.32299 in.) Mark 2 59.005 to 59.006 mm (2.32303 to 2.32307 in.) Mark 3 59.007 to 59.009 mm (2.32311 to 2.32318 in.) Mark 4 59.010 to 59.011 mm (2.32322 to 2.32326 in.) Mark 5 59.012 to 59.013 mm (2.32330 to 2.32334 in.) Mark 6 59.014 to 59.016 mm (2.32338 to 2.32346 in.) Standard Crankshaft Main Journal Diameter (B) Item Specified Condition Mark 0 54.999 to 55.000 mm (2.16531 to 2.16535 in.) Mark 1 54.997 to 54.998 mm (2.16523 to 2.16527 in.) Mark 2 54.995 to 54.996 mm (2.16515 to 2.16519 in.) Mark 3 54.993 to 54.994 mm (2.16507 to 2.16511 in.) Mark 4 54.991 to 54.992 mm (2.16500 to 2.16504 in.) Mark 5 54.988 to 54.990 mm (2.16488 to 2.16496 in.) Standard Bearing Center Wall Thickness Item Specified Condition Mark 1 1.991 to 1.994 mm (0.07839 to 0.07850 in.) Mark 2 1.995 to 1.997 mm (0.07854 to 0.07862 in.) Mark 3 1.998 to 2.000 mm (0.07866 to 0.07874 in.) Mark 4 2.001 to 2.003 mm (0.07878 to 0.07886 in.) Perform the inspection above for each journal.
11. INSPECT CRANKSHAFT BEARING CAP BOLT Using a vernier caliper, measure the diameter of the tension portion of the bolts. Measuring point 58.5 mm (2.30 in.) Standard diameter 9.77 to 9.96 mm (0.385 to 0.392 in.) Minimum diameter 9.1 mm (0.358 in.) TEXT IN ILLUSTRATION *1 Measuring Point If the diameter is less than the minimum, replace the crankshaft bearing cap bolt.
12. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the diameter of the tension portion of the bolt. Standard diameter 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter 8.3 mm (0.327 in.) TEXT IN ILLUSTRATION *1 Tension Portion If the diameter is less than the minimum, replace the connecting rod bolt.
13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. If stuck, replace the No. 1 oil nozzle. Push the check valve with a pin to check if it moves smoothly. If the valve does not move smoothly, clean or replace the No. 1 oil nozzle. Apply air into A. Check that air does not leak through B. If air leaks, clean or replace the No. 1 oil nozzle. Push the check valve while applying air into A. Check that air passes through B. If air does not pass through B, clean or replace the No. 1 oil nozzle.
14. INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. If stuck, replace the No. 2 oil nozzle. Push the check valve with a pin to check if it moves smoothly. If the valve does not move smoothly, clean or replace the No. 2 oil nozzle. While covering A, apply air into B. Check that air does not leak through C. Perform the check again while covering B and applying air into A. If air leaks, clean or replace the No. 2 oil nozzle. Push the check valve while covering A, and apply air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and applying air into A. If air does not pass through C, clean or replace the No. 2 oil nozzle.

Scheme 327

Scheme 328

1. REPLACE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Remove the 12 ring pins. Using a plastic-faced hammer, install 12 new ring pins. TEXT IN ILLUSTRATION *A Upper Side *B Lower Side *1 Protrusion Height - - Standard Protrusion Height Item Specified Condition A 5.0 to 7.0 mm (0.197 to 0.276 in.) B 4.0 to 7.0 mm (0.157 to 0.276 in.)
2. REPLACE STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Remove the 14 straight pins. Using a plastic-faced hammer, install 14 new straight pins. TEXT IN ILLUSTRATION *A Front Side *B Rear Side *C LH Side *D Lower Side *E RH Side - - *1 Protrusion Height - - Standard Protrusion Height Item Specified Condition A 11.0 to 13.0 mm (0.433 to 0.512 in.) B 5.0 to 7.0 mm (0.197 to 0.276 in.)

HINT

Perform "Inspection After Repairs" after replacing the piston sub-assembly or piston ring. Refer to INITIALIZATION [05/2013 - ] .

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

1. INSTALL STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. Using an E8 and E10 "TORX" socket wrench, install the stud bolts. for stud bolt A Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) for stud bolt B Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION *A RH Side *B LH Side
2. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 2 oil nozzles with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. INSTALL PISTON HINT: Perform "Inspection After Repairs" after replacing the piston sub-assembly. Refer to «INITIALIZATION [05/2013 - ]»(ref-615120-S07565023022014050900000) . Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Gradually heat the piston up to 80 to 90°C (176 to 194°F). Coat the piston, piston pin and connecting rod with engine oil. Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the pin comes into contact with the snap ring. TEXT IN ILLUSTRATION *1 Front Mark HINT: The piston and pin are a matched set. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Hole Cutout Portion HINT: Be sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston. Check the fitting condition between the piston and piston pin. Move the connecting rod back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. Rotate the piston back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set.
5. INSTALL PISTON RING SET HINT: Perform "Inspection After Repairs" after replacing the piston ring. Refer to «INITIALIZATION [05/2013 - ]»(ref-615120-S07565023022014050900000) . Install the oil ring expander and oil ring by hand. TEXT IN ILLUSTRATION *1 Oil Ring *2 Oil Ring Expander *3 Coil Joint *4 Oil Ring End HINT: Arrange the oil ring ends and coil joint as shown in the illustration. Using a piston ring expander, install the 2 compression rings with the code mark positioned as shown in the illustration. Piston Ring Mark Item Code Mark Paint Mark No. 1 1NA Blue No. 2 2N Yellow TEXT IN ILLUSTRATION *1 No. 1 Compression Ring *2 No. 2 Compression Ring *3 Code Mark *4 Paint Mark Upward NOTE: Install the compression ring with the code mark facing upward.
6. INSTALL CRANKSHAFT PULLEY KEY Install the 2 crankshaft pulley keys to the crankshaft.
7. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearing. Install the upper bearing to the cylinder block as shown in the illustration. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT NOTE: Do not apply engine oil to the bearings or their contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one. Install the lower bearing to the bearing cap. Using a vernier caliper, measure the distance between the edges of the crankshaft bearing cap and lower bearing. Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) TEXT IN ILLUSTRATION *1 Vernier Caliper NOTE: Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
8. INSTALL CRANKSHAFT THRUST WASHER Apply engine oil to the thrust washers. Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward. TEXT IN ILLUSTRATION *1 Oil Groove
9. INSTALL CRANKSHAFT Apply engine oil to the upper bearing, and then install the crankshaft to the cylinder block. Examine the front marks and numbers, and then install the bearing caps to the cylinder block with the front marks as shown in the illustration. TEXT IN ILLUSTRATION *1 Front Mark Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Tighten the crankshaft bearing cap bolts. HINT: The cap bolts are tightened in 3 progressive steps. Step 1: Using several steps, install and uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Step 2: Tighten the 10 bearing cap bolts again in the sequence shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) If a crankshaft bearing cap bolt does not meet the specified torque, replace it. Mark the front side of each crankshaft bearing cap bolt with paint. Step 3: Tighten the 10 bearing cap bolts 90° in the order shown in step 1. Check that the paint marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.
10. INSTALL CONNECTING ROD BEARING Clean the bearing contact surface of the connecting rod and cap, and both surfaces of both bearings. Install the connecting rod bearings to the connecting rods and connecting rod caps. Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the edges of the bearing cap and connecting rod bearing. Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.) TEXT IN ILLUSTRATION *1 Vernier Caliper NOTE: Do not apply engine oil to the bearings or the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
11. INSTALL PISTON WITH CONNECTING ROD Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 Front Mark *2 No. 2 Compression Ring *3 No. 1 Compression Ring *4 Oil Ring *5 Oil Ring (Expander) Front Using a hammer handle and piston ring compressor, press a piston with connecting rod into each cylinder with the front mark of the piston facing forward. TEXT IN ILLUSTRATION *1 Front Mark NOTE: When inserting the piston with connecting rod into the cylinder block, make sure the oil nozzle does not interfere with the connecting rod. HINT: The front mark is "2L" printed in raised letters. Check that the front mark of the connecting rod cap is facing in the correct direction. TEXT IN ILLUSTRATION *1 Front Mark NOTE: Match the numbered connecting rod cap with the correct connecting rod. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts. Install the connecting rod bolts. HINT: The connecting rod bolts are tightened in 2 progressive steps. Step 1: Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Mark the front side of each connecting rod cap bolt with paint. Step 2: Tighten the cap bolts 90°. Check that the paint marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.