Main Index GROUP 11B Group TOC ENGINE OVERHAUL <4A9> CONTENTS GENERAL INFORMATION . . . . . . . . 11B-2 GENERAL SPECIFICATIONS . . . . . . 11B-2 SERVICE SPECIFICATIONS. . . . . . . 11B-2 TORQUE SPECIFICATIONS . . . . . . . 11B-4 SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-6 SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-7 ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-9 REMOVAL AND INSTALLATION . . . . . . . . FUEL AND EMISSION PARTS . . . . .
11B-2 ENGINE OVERHAUL <4A9> GENERAL INFORMATION GENERAL INFORMATION M1113000100976 Vehicle name Colt Vehicle model Engine model Z23A 4A91 Displacement Specification mL 1,499 Double overhead camshaft, 16-valve GENERAL SPECIFICATIONS M1113000200962 Item 4A91 Total displacement mL 1,499 Bore × stroke mm 75.0 × 84.8 Compression ratio 10.
11B-3 ENGINE OVERHAUL <4A9> SERVICE SPECIFICATIONS Item Standard value Limit Intake 1.35 0.85 Exhaust 1.85 1.35 Intake 4.965 − 4.980 − Exhaust 4.955 − 4.970 − 45°− 45.5° − Intake 0.020 − 0.047 0.10 Exhaust 0.030 − 0.057 0.15 Intake 89.61 89.11 Exhaust 90.94 90.44 Intake 38.46 38.96 Exhaust 38.49 38.99 Valve spring free length mm 43.1 42.1 Valve spring load / installed height N/mm 152/33.
11B-4 ENGINE OVERHAUL <4A9> TORQUE SPECIFICATIONS Item Standard value Limit Cylinder bore mm 75 − Cylindrically mm 0.007 or less − Piston to cylinder clearance mm 0.010 − 0.035 − Main Index Group TOC TORQUE SPECIFICATIONS M1113023401788 Items N⋅m ALTERNATOR AND IGNITION SYSTEM Spark plugs 25 ± 5 Ignition coil bolt 8.4 ± 0.6 Tensioner pulley bolts 49 ± 9 Crankshaft pulley bolts 190 Water pump pulley bolts 8.4 ± 0.65 Adjust bolt 5.0 ± 1.
11B-5 ENGINE OVERHAUL <4A9> TORQUE SPECIFICATIONS Items N⋅m Inlet manifold stay bolts 13.4 ± 6.4 Inlet manifold stay nuts 13.4 ± 6.4 EXHAUST MANIFOLD Exhaust manifold bracket A bolts 20 ± 1.6 Exhaust manifold bracket B bolts 34.5 ± 6.5 Exhaust manifold nuts 35 ± 2 Heat protector bolts 6.0 ± 1.0 OIL PAN AND TIMING CHAIN CASE Timing chain case bolts (M10) 39.5 ± 3.0 Timing chain case bolts (M6) 8.4 ± 0.6 Water pump bolts 8.4 ± 0.6 Cover bolts 8.4 ± 0.6 Oil screen bolts 11.5 ± 1.
11B-6 ENGINE OVERHAUL <4A9> SEALANTS SEALANTS M1113000500888 Application points Specified sealant Cylinder block rear oil seal mounting face LOCTITE 5971 or exact equivalent Balancer shaft side cover LOCTITE 5971 or exact equivalent Oil pan LOCTITE 5971 or exact equivalent Cylinder head cover LOCTITE 5971 or exact equivalent Timing chain case LOCTITE 5971 or exact equivalent Cylinder block crank angle sensor mounting face LOCTITE 5971 or exact equivalent Drine plate bolt LOCTITE 2701 or eq
11B-7 ENGINE OVERHAUL <4A9> SPECIAL TOOLS SPECIAL TOOLS M1113000601628 Tool Number Name Use MD998781 Flywheel stopper Retention of flywheel MB991883 Flywheel stopper Retention of flywheel MD998727 Oil pan remover Removal of oil pan MB990699 Differential oil seal installer Installation of front oil seal MB991993 Crankshaft front oil seal guide Installation of chain case MB992000 Crankshaft adapter Turn the crankshaft MD999597 Valve spring compressor Compression of valve spring D99
11B-8 ENGINE OVERHAUL <4A9> SPECIAL TOOLS Tool MB991614 Number Name Use MB991994 Valve stem seal installer Installation of valve stem seal (Use the special tool, on which the number "MB991994" is stamped.
11B-9 ENGINE OVERHAUL <4A9> ALTERNATOR AND IGNITION SYSTEM ALTERNATOR AND IGNITION SYSTEM Main Index REMOVAL AND INSTALLATION M1113001001306 Group TOC 8.4 ± 0.6 N·m 25 ± 5 N·m 11 2 12 1 7.6 ± 0.6 N·m 3 49 ± 9 N·m 10 11 ± 1 N·m (Hexagon bolt) 8.4 ± 0.6 N·m (Torx bolt) 5 36 ± 3.6 N·m 22.5 ± 2.5 N·m 9 190 N·m 5.0 ± 1.0 N·m 7 4 47 ± 5 N·m 8 6 8.4 ± 0.65 N·m AK403224AB 1. 2. 3. 4. 5. 6. <> >>A<< 7.
11B-10 ENGINE OVERHAUL <4A9> ALTERNATOR AND IGNITION SYSTEM REMOVAL SERVICE POINTS <> CRANKSHAFT PULLEY BOLT REMOVAL Main INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT PULLEY / WASHER Index / CRANKSHAFT PULLEY BOLT INSTALGroup LATION TOC MB991883 MB991883 AK600409AB AK600410AC MD998781 MD998781 Cylinder block Cylinder block Drive plate AK600407AB Drive plate 1. Lock the drive plate or the flywheel with the special tool Flywheel Stopper. 2. Remove the crankshaft bolt.
B-11 ENGINE OVERHAUL <4A9> FUEL AND EMISSION PARTS FUEL AND EMISSION PARTS Main Index REMOVAL AND INSTALLATION M1113002200894 Group TOC 18.4 ± 1.4 N·m 15 1 14 13 12 3 9 10 2 4 11 7.6 ± 0.6 N·m 6.0 ± 0.5 N·m 18.4 ± 1.4 N·m 8 6.0 ± 0.5 N·m 5 7 6 AK401777AC Removal steps Vacuum hose Vacuum hose Solenoid valve Engine hanger Radiator upper hose clamp Throttle body Throttle body gasket Manifold absolute pressure (MAP) sensor >>A<< 9. Delivery pipe assembly 1. 2. 3. 4. 5. >>D<< 6. >>C<< 7.
11B-12 ENGINE OVERHAUL <4A9> FUEL AND EMISSION PARTS INSTALLATION SERVICE POINTS >>A<< DELIVERY PIPE ASSEMBLY INSTALLATION CAUTION Be sure not to allow engine oil entering into the delivery pipe. 1. Lightly coat the injector's O-rings with new engine oil. Insert the injector squarely into the delivery pipe. Do not insert it aslant. 2. Ensure that the injector can rotate smoothly.
11B-13 ENGINE OVERHAUL <4A9> INLET MANIFOLD INLET MANIFOLD Main Index REMOVAL AND INSTALLATION M1113026100385 Group TOC 7.6 ± 0.6 N·m 11 12 2 1 13.4 ± 6.4 N·m 7.6 ± 0.6 N·m 20 ± 1 N·m 29.4 ± 9.8 N·m 13 7 10 5 8.4 ± 0.6 N·m 10 ± 2 N·m 3 4 20 ± 1 N·m 6 8.4 ± 0.6 N·m 1. 2. >>E<< 3. 4. 5. >>D<< 6. >>C<< 7. 8 9 Removal steps Inlet manifold Inlet manifold gasket Oil pressure switch Detonation sensor Camshaft position sensor Crank angle sensor Engine coolant temperature sensor 8.4 ± 0.
11B-14 ENGINE OVERHAUL <4A9> INLET MANIFOLD Main Index 7.6 ± 0.6 N·m Group TOC 20 21 11 10 13.4 ± 6.4 N·m 7.6 ± 0.6 N·m 20 ± 1 N·m 29.4 ± 9.8 N·m 22 16 19 18 ± 1 N·m 14 6 8.4 ± 0.6 N·m 5 9 7 10 ± 2 N·m 12 4 3 7.6 ± 0.6 N·m 8 13 13.4 ± 6.4 N·m 2 1 20 ± 1 N·m 15 8.4 ± 0.6 N·m Removal steps 1. Inlet manifold stay 2. Special bolt 3. EGR valve >>G<< 4. EGR valve gasket 5. EGR inlet pipe 6. Insulator gasket 7. EGR pipe >>F<< 8. EGR pipe gasket B >>F<< 9. EGR pipe gasket A 10.
11B-15 ENGINE OVERHAUL <4A9> INLET MANIFOLD INSTALLATION SERVICE POINTS >>A<< WATER PIPE ASSEMBLY GASKET INSTALLATION Projection Main >>C<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION Index CAUTION Be careful not to damage the connector portion (made of resin) of the sensor with the tool. AK304915AB 1. Place the water pipe assembly gasket onto the cylinder block, facing the gasket's protruded portion in the illustrated direction. Water pipe assmeblly A AK400587AD 1.
11B-16 ENGINE OVERHAUL <4A9> INLET MANIFOLD 3. Install the crank angle sensor onto the cylinder block by tightening it to 8.4 ± 0.6 N⋅m. >>F<< EGR PIPE GASKET INSTALLATION Main Index Projection >>E<< OIL PRESSURE SWITCH INSTALLATION EGR pipe CAUTION Apply sealant correctly so that it will not be squeezed out onto the end of the threaded portion upon assembly. 1 mm Projection AK401779AC 5 mm 1. Install the EGR pipe gasket A, facing the gasket’s protruded portion in the illudtrated direction.
11B-17 ENGINE OVERHAUL <4A9> EXHAUST MANIFOLD EXHAUST MANIFOLD Main Index REMOVAL AND INSTALLATION M1113004901171 Group TOC 6.0 ± 1.0 N·m 2 35 ± 2 N·m 3 30 ± 3 N·m 4 20 ± 1.6 N·m 5 1 34.5 ± 6.5 N·m AK402837AC Removal steps >>B<< 1. Exhaust manifold bracket B 2. Heat protector 3. Exhaust manifold Removal steps (Continued) >>A<< 4. Exhaust manifold gasket 5.
11B-18 ENGINE OVERHAUL <4A9> EXHAUST MANIFOLD INSTALLATION SERVICE POINTS >>A<< EXHAUST MANIFOLD GASKET INSTALLATION >>B<< EXHAUST MANIFOLD BRACKET B Main Index INSTALLATION Group TOC Exhaust manihold bracket B Exhaust manihold bracket A AK304919AC Projection AK402346AC Install the exhaust manifold gasket, facing the gasket's protruded portion in the illustrated direction.
11B-19 ENGINE OVERHAUL <4A9> OIL PAN AND TIMING CHAIN CASE OIL PAN AND TIMING CHAIN CASE Main Index REMOVAL AND INSTALLATION M1113026300282 Group TOC 5 1 E - E 9.0 ± 1.0 N·m 4 11 3 2 12 18 8 10 9 20 8.4 ± 0.6 N·m 15 14 39.5 ± 3.0 N·m 11.5 ± 1.1 N·m 11.5 ± 1.1 N·m 19 8.4 ± 0.6 N·m 16 6 17 8.4 ± 0.6 N·m 7 9.5 ± 0.5 N·m 39 ± 5 N·m 13 AK600402AE Removal steps 1. Breather hose 2. PCV hose 3. PCV valve 4. PCV valve gasket 5. Oil filler cap 6. Oil drain plug 7.
11B-20 ENGINE OVERHAUL <4A9> OIL PAN AND TIMING CHAIN CASE Main Index 5 Group TOC 1 E - E 9.0 ± 1.0 N·m 4 12 3 2 13 19 10 11 9 21 8.4 ± 0.6 N·m 16 15 39.5 ± 3.0 N·m 11.5 ± 1.1 N·m 11.5 ± 1.1 N·m 20 8.4 ± 0.6 N·m 17 20 ± 1 N·m 8 6 18 8.4 ± 0.6 N·m 7 9.5 ± 0.5 N·m 39 ± 5 N·m 14 AK402675AE Removal steps 1. Breather hose 2. PCV hose 3. PCV valve 4. PCV valve gasket 5. Oil filler cap 6. Oil drain plug 7. Oil drain plug gasket <> >>F<< 8. Oil filter 9. Oil filter bracket 10.
11B-21 ENGINE OVERHAUL <4A9> OIL PAN AND TIMING CHAIN CASE REMOVAL SERVICE POINTS <> OIL FILTER REMOVAL >>B<< TIMING CHAIN CASE INSTALLATION Main Index 1. Remove any liquid gasket remaining on the timing chain case, the cylinder block, and the cylinder Group head. TOC Oil filter wrench AK401774 AC Remove the oil filter using an oil filter wrench (commercially available). <> OIL PAN REMOVAL MB991993 AK305517AB 2. Install the special tool Oil seal guide (MB991993) onto the crankshaft.
11B-22 ENGINE OVERHAUL <4A9> OIL PAN AND TIMING CHAIN CASE >>C<< OIL PAN INSTALLATION 1. Remove any liquid gasket remaining on the cylinder block, the timing chain case, the oil seal case and the oil pan. A A CAUTION The oil pan should be installed within 3 minutes of applying liquid gasket. A B E C(cover) C E D D A A A B A A B A : 6×25 B : 6×30 C : 6×45 D : 10×50 E : 10×90 AK402395AC AK402647AC 5. Tighten the chain case retaining bolts to the specified torques. Tightening torque: M6 8.
11B-23 ENGINE OVERHAUL <4A9> OIL PAN AND TIMING CHAIN CASE >>D<< CYLINDER HEAD COVER INSTALLATION 1. Remove any liquid gasket remaining on the cylinder head cover, the timing chain case and the cylinder head. Main CAUTION The cover should be installed within 3 minutes of Index applying liquid gasket. 2. Apply a 2.0 ± 0.5 mm bead of liquid gasket as illustrated. Specified sealant: LOCTITE 5971 or exact equivalent >>F<< OIL FILTER INSTALLATION 1. Clean the filter mounting surface on the cylinder block.
11B-24 ENGINE OVERHAUL <4A9> TIMING CHAIN TIMING CHAIN Main Index REMOVAL AND INSTALLATION M1113026600216 Group TOC 88 ± 10 N·m 6 8 5 23.5 ± 4.5 N·m 1 2 7 64.9 ± 5.9 N·m 3 8.4 ± 0.6 N·m 4 10 ± 2 N·m AK402345AE >>D<< 1. 2. 3. >>C<< 4. <> >>B<< 5. Removal steps Timing chain tensioner assembly Tensioner lever assembly Chain guide assembly Timing chain Camshaft sprocket bolt Removal steps (Continued) 6. Camshaft sprocket <> >>A<< 7. V.V.T. sprocket bolt 8. V.V.T.
ENGINE OVERHAUL <4A9> TIMING CHAIN REMOVAL SERVICE POINTS <> CAMSHAFT SPROCKET BOLT REMOVAL 11B-25 1. Apply a proper minimum quantity of engine oil to Main Index the following points. • Camshaft end • Insertion hole in V.V.T. sprocket (all over inside Group and outside surfaces) TOC • Threads and head of V.V.T. sprocket bolt • Bearing surface of V.V.T. sprocket bolt 2. Install the V.V.T. sprocket onto the camshaft. 3. Make sure that the V.V.T. sprocket is installed all the way onto the camshaft.
11B-26 ENGINE OVERHAUL <4A9> TIMING CHAIN >>C<< TIMING CHAIN INSTALLATION Timing mark Camshaft sprocket timing mark Main Index Timing mark Timing chain mark link plate (blue) Group TOC V.V.T. sprocket timing mark AK304926 AB Timing mark Crankshaft sprocket timing mark Timing chain mark link plate (blue) AK305394AB 1. Place the timing chain such that the blue link that is away from the other two blue links of the chain is on the crankshaft side. Timing Mark 4.
11B-27 ENGINE OVERHAUL <4A9> TIMING CHAIN INSPECTION M1113026700075 VALVE CLEARANCE MEASUREMENT Measure the valve clearance as illustrated. Group TOC Groove Dowel pin MB992000 AK304936 Crankshaft Crankshaft pulley bolt and washer AC312116AB Set the special tool Crankshaft adapter (MB992000) to the crankshaft, and install the crankshaft pulley bolt and washer. 3. Using a thickness gauge, measure the clearance between the cam base circle and the valve tappet.
11B-28 ENGINE OVERHAUL <4A9> TIMING CHAIN NOTE: Valve tappets are available in 31 sizes, at 0.02 mm intervals in the 2.70 − 3.30 mm range. Wall thickness AK304938 AB 9. Valve tappets should be selected in the following manner. (1) Remove the valve tappet and measure its thickness. (2) Calculate the correct thickness for a new valve Main Index tappet as follows that achieves the standard valve clearance.
11B-29 ENGINE OVERHAUL <4A9> CAMSHAFT CAMSHAFT Main Index REMOVAL AND INSTALLATION M1113026900110 Group TOC 11 ± 1 N·m 7 20 ± 1 N·m 9 6 8 Apply engine oil to all moving parts before installation. 10 2 1 7.6 ± 0.6 N·m 5 4 3 44 ± 5 N·m AK402341AC Removal steps >>D<< 1. Oil feeder control valve (OCV) >>D<< 2. O-ring 3. Oil feeder control valve (OCV) filter bolt 4. Gasket >>C<< 5. Oil feeder control valve (OCV) filter <> >>B<< 6.
11B-30 ENGINE OVERHAUL <4A9> CAMSHAFT REMOVAL SERVICE POINTS <> FRONT CAMSHAFT BEARING CAP / CAMSHAFT BEARING CAP REMOVAL Main Index E 2 Identification mark Cap No. Group TOC 1 8 4 5 7 3 2 6 1 3 3 7 3 4 8 6 1 5 1 5 2 7 3 6 2 4 8 6 2 4 8 1 2 AK306130AB In accordance with the numerical order shown in the illustration, remove the front camshaft bearing cap first, and then remove the installation bolt of each camshaft bearing cap.
ENGINE OVERHAUL <4A9> CAMSHAFT >>D<< OIL FEEDER CONTROL VALVE (OCV) INSTALLATION CAUTION • Do not reuse the O-ring. • Install the O-ring after wrap a tape not having adhesion (such as a seal tape) round the notch on the oil passage of OCV to prevent it from damage. The damaged O-ring may cause oil leakage. Tape AK303651AE 1. Apply a little amount of engine oil to the O-ring of OCV. 2. Install the OCV to the cylinder head. 3. Tighten the OCV to the specified torque of 7.6 ± 0.6 N⋅m.
11B-32 ENGINE OVERHAUL <4A9> CAMSHAFT INSPECTION VALVE TAPPET Main Index M1113027000091 CAMSHAFT Wall thickness Group TOC AK304938 AB AK304883 Measure the cam height. If the measured value exceeds the limit, replace the camshaft. Standard value: Intake: 44.71 mm Exhaust: 44.28 mm 1. Measure the valve tappet at the illustrated location. If the measured valve is discord to instruction valve by identification mark and following table, replace the tappet. Identification mark Limit: Intake: 44.
11B-33 ENGINE OVERHAUL <4A9> CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES Main Index REMOVAL AND INSTALLATION M1113006900992 24.5 ± 2 N·m → +180˚ to 184˚ 1 6 10 9 2 11 5 13 7 15 14 16 17 18 19 20 8 21 12 3 4 Apply engine oil to all moving parts before installation. AK402342AC Removal steps >>C<< 1. Cylinder head bolt 2. Cylinder head bolt washer 3. Cylinder head assembly 4. Cylinder head gasket <> >>B<< 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8.
11B-34 ENGINE OVERHAUL <4A9> CYLINDER HEAD AND VALVES REMOVAL SERVICE POINTS <> RETAINER LOCK REMOVAL >>B<< RETAINER LOCK INSTALLATION Main Index MD999597 Group TOC MD999597 AK304941AB AK304941AB While compressing the valve spring using the special tool Valve spring compressor (MD999597), remove the retainer lock.
11B-35 ENGINE OVERHAUL <4A9> CYLINDER HEAD AND VALVES 2. Remove oil, scale, sealant, carbon and other residues completely. Clean the oil passages and blow compressed air through them to verify that they are free of restriction. Timing chain side 8 4 2 5 9 10 6 1 3 7 AK305406AB 3. In accordance with the installation order, tighten them to the specified torque of 24.5 ± 2 N⋅m in several steps. 4. Make sure all bolts reach the specified torque. Paint mark 180˚ to 184˚ Paint mark AK304945 AB 5.
11B-36 ENGINE OVERHAUL <4A9> CYLINDER HEAD AND VALVES VALVE GUIDE Main Index Group TOC Valve guide Length AK305409AB 3. Measure the valve overall length. If the measured value exceeds the limit, replace with a new valve. Standard value: Intake 89.61 mm Exhaust 90.94 mm Limit: Intake 89.11 mm Exhaust 90.44 mm Stem diameter AK300168 AE Guide inside diameter Measure the clearance between the valve guide and the valve stem.
11B-37 ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD PISTON AND CONNECTING ROD Main Index REMOVAL AND INSTALLATION M1113008401457 Group TOC 6 7 8 10 4 9 Apply engine oil to all moving parts before installation. 11 5 3 2 1 15 ± 2 N·m → +90˚ to 94˚ AK402343AC >>G<< <> >>F<< >>E<< >>D<< >>E<< >>C<< >>C<< 1. 2. 3. 4. 5. 6. 7. Removal steps Connecting rod cap bolt Connecting rod cap Connecting rod bearing Piston, connecting rod assembly Connecting rod bearing Piston ring, No.
11B-38 ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD REMOVAL SERVICE POINTS <> CONNECTING ROD CAP REMOVAL Main Index Push rod Piston pin Cylinder No. Front mark Front mark Guide D AK304890AC To facilitate reassembly, mark the side face of the connecting rod big end with the corresponding cylinder number. Base <> PISTON PIN REMOVAL Guide A: 17.9 mm Push rod Guide B Guide A: 18.9 mm Guide C Guide A: 20.9 mm Base Guide D (MB991659) Guide A: 21.9 mm AK305415AB AK305425AB 1.
11B-39 ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD 2. Assemble the piston and the connecting rod together, ensuring that their front marks are aligned with each other. 3. Apply engine oil onto the periphery of the piston pin. 4. Insert the piston pin assembled in step 1 above into the piston pin boss. Guide A end of the piston pin should be inserted first into the front mark end of the boss. L >>B<< OIL RING INSTALLATION 1.
11B-40 ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD >>C<< PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION >>D<< PISTON, CONNECTING ROD ASSEMBLY INSTALLATION 1. Apply engine oil sufficiently onto the piston periphery, the piston rings and the oil ring. Piston ring expander No. 1 Side rail Piston pin AK304892AB Use a piston ring expander to install the No. 1 and No. 2 piston rings. The ring identification mark should face upwards. Identification mark Size marks No. 1 No.
11B-41 ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD >>E<< CONNECTING ROD BEARING INSTALLATION >>F<< CONNECTING ROD CAP INSTALLATION Main Index Group TOC Cylinder No. Identification color AK305607AB 1. Connecting rod bearings are color coded with paint at the illustrated locations. Bearings should be selected based on the following table. Front mark AK304890AC 1. Install the correct bearing cap onto the corresponding connecting rod, based on the marking placed during disassembly.
11B-42 ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD >>G<< CONNECTING ROD CAP BOLT INSTALLATION 4. Alternately, tighten the bolts in several steps to the Main Index specified torque of 15 ± 2 N⋅m. 1. Inspect all reused connecting rod bolts according to the following procedure. 90˚ to 94˚ 15 mm Paint mark Paint mark AK304894AC 30 mm AK401052AB (1) Measure the outside diameter at 15 mm and 30 mm from the head of the connecting rod bolts shown in Figure respectively.
ENGINE OVERHAUL <4A9> PISTON AND CONNECTING ROD INSPECTION M1113008500837 PISTON RING 11B-43 CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAGE METHOD) Main Index 1. Wipe off oil from the crankshaft pin and the connecting rod bearings. 2. Place a plastigage, with a length equal to the bearing width, onto the crank pin in the axial direction. Group TOC Plastigage AK304899 1. Measure the clearance between the piston ring and the ring groove.
11B-44 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK Main Index REMOVAL AND INSTALLATION M1113008701801 Group TOC 2 1 100 ± 5 N·m 6.7 ± 1.3 N·m 3 7.6 ± 0.6 N·m 4 12 10 9 8 11 Apply engine oil to all moving parts before installation. 7 6 9.0 ± 1.0 N·m 5 35 ± 2 N·m → +60˚ to 64˚ AK600324AB <> >>G<< 1. 2. 3. 4. >>F<< 5. >>E<< 6.
11B-45 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK Main Index 2 1 100 ± 5 N·m 6.7 ± 1.3 N·m 3 7.6 ± 0.6 N·m 4 5 13 11 10 9 12 Apply engine oil to all moving parts before installation. 8 7 9.0 ± 1.0 N·m 6 35 ± 2 N·m → +60˚ to 64˚ AK401772 AC <> >>G<< 1. 2. 3. 4. >>F<< 5. >>E<< 6. >>E<< 7. >>D<< 8.
11B-46 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK REMOVAL SERVICE POINTS <> DRIVE PLATE BOLT/FLYWHEEL BOLT REMOVAL Main >>B<< THRUST BEARING INSTALLATION Index 1. Install the thrust bearing onto the cylinder block side of the No. 4 bearing. Apply engine oil to the thrust bearing to facilitate installation. MB991883 AK600410AC Groove AK305429AB 2. The thrust bearing should be installed such that its groove faces the crankshaft weight.
11B-47 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK Cylinder block Identification mark Journal diameter mm Main Index Crankshaft bearing paint color 1 50.000 − 50.005 Blue 2 50.005 − 50.010 Black 3 50.010 − 50.015 Red Group TOC Identification color AK305607AB A 2. Every crankshaft bearing lower is identified by the paint mark at the illustrated location. AK305700AC 3. Select and install the crankshaft bearing upper. 4. Measure the illustrated location. The error should be within 0.
11B-48 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK >>E<< BEARING CAP / BEARING CAP BOLT INSTALLATION Cap No. 3 2 1 7 3 9 5 1 5 4 4 8 2 6 Main CAUTION • If the bolt is tightened less than the specified Index lower limit of 60 degree angle, the bolt may become loose. Be sure to tighten correctly. Group • If the bolt is tightened in excess of the speciTOC fied upper limit of 64 degree angle, loosen the nut completely and repeat the entire procedures. 10 MB991614 AK305612 AB 1.
11B-49 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK >>F<< OIL SEAL CASE INSTALLATION Main Index 1. Remove any liquid gasket remaining on the oil seal case and the cylinder block. CAUTION The oil seal case should be installed within 3 minutes of applying liquid gasket. MB991883 Cylinder block AK600409AB MD998781 AK305614AB 2. Apply a 2.0 ± 0.5 mm bead of liquid gasket as illustrated. Specified sealant: LOCTITE 5971 or equivalent 3.
11B-50 ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK INSPECTION CYLINDER BLOCK M1113008800849 CRANKSHAFT OIL CLEARANCE (USING PLASTIGAGE) 1. Check visually for scoring, rust, or corrosion. Perform liquid penetrant test etc. to check for cracks. If faulty, replace. Oil clearance can be measured easily by using "plastigage." Use the "plastigage" in the following manner. 1. Wipe off oil from the surfaces of the crankshaft journals as well as the inner surfaces of the bearings. 2.
ENGINE OVERHAUL <4A9> CRANKSHAFT AND CYLINDER BLOCK BORING CYLINDERS 11B-51 Main 3. Based on the measured piston outside diameter Index (O.D.), calculate the boring finish dimension. Boring finish dimension = Piston O.D. + 0.015 − 0.035 mm (Clearance between piston Group O.D. and cylinder) - 0.02 mm (honing margin) 4. Bore each cylinders to the calculated boring finish dimension. A AK401446AB 1. Oversize pistons should be based on the largest bore cylinder. Size Size mark 0.
