13521923-13521924-13521925

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Use fender covers to avoid damaging painted surfaces.

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To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.

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When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.

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To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

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Mark all wiring and hoses to avoid misconnection.

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Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.

Remove the engine and transaxle assembly.

(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")

Remove the transaxle assembly from the engine assembly.

Manual Transaxle : (Refer to Manual Transaxle System - "Manual Transaxle")

Automatic Transaxle : (Refer to Automatic Transaxle System - "Automatic Transaxle")

Manual Transaxle : Remove the flywheel.

(Refer to Cylinder Block - "Flywheel")

Automatic Transaxle : Remove the drive plate.

(Refer to Cylinder Block - "Drive Plate")

Remove the encoder and the rear oil seal case assembly.

(Refer to Cylinder Block - "Rear Oil Seal")

Install the engine assembly to engine stand for disassembly.

Remove the intake manifold.

(Refer to Intake And Exhaust System - "Intake Manifold")

Remove the EGR & thermostat housing assembly.

(Refer to Cooling System - "Water Temperature Control Assembly")

Remove the exhaust manifold.

(Refer to Intake And Exhaust System - "Exhaust Manifold")

Remove the lower oil pan and upper oil pan.

(Refer to Lubrication System - "Oil Pan")

10.

Remove the balance shaft & oil pump module.

(Refer to Lubrication System - "Balance Shaft & Oil Pump")

11.

Remove the timing chain.

(Refer to Timing System - "Timing Chain")

12.

Remove the cylinder head.

(Refer to Cylinder Head Assembly - "Cylinder Head")

13.

Check the connecting rod side clearance.

14.

Check the connecting rod bearing cap oil clearance.

15.

Remove the piston and connecting rod assemblies .

(1)

Using a ridge reamer, remove all the carbon from the top of the cylinder.

(2)

Remove the connecting rod bearing caps (A).

caution

Mark the connecting rod, and caps to be able to reassemble in the original position and direction.

(3)

Push the piston and connecting rod assembly with upper bearing through the top of the cylinder block.

caution

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Keep the connecting rod ands cap with their bearings assembled together.

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Arrange the piston and connecting rod assemblies in the correct order.

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Mark the piston and connecting rod assemblies to be able to reassemble in the original position.

16.

Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

17.

Disassemble the piston rings.

(1)

Using a piston ring expender, remove the 2 compression rings (A).

(2)

Remove the oil ring and coil spring (B) by hand.

note

Do not apply excessive force to remove the oil ring from piston. It may cause to break the oil ring.

caution

Arrange the piston rings in the correct order only.

18.

Disassemble the connecting rod from the piston.

(1)

Remove the snap ring (C) from the piston.

(2)

Using a press, remove the piston pin (D) from piston.

(3)

Disassemble the piston (F) and connecting rod (E).

Check the end play between piston and connecting rod.

Side clearance :

0.05 ~ 0.31 mm (0.0020 ~ 0.0122 in)

If out-of-tolerance, install a new connecting rod.

If still out-of-tolerance after connecting rod replacement, replace the crankshaft.

Check the connecting rod bearing oil clearance.

(1)

Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.

(2)

Remove the 2 connecting rod cap bolts.

(3)

Remove the connecting rod cap and lower bearing.

(4)

Clean the crankshaft pin journal and bearing.

(5)

Place a plastigage across the crankshaft pin journal.

(6)

Reinstall the lower bearing and cap, and tighten the bolts.

Tightening torque :

27.5~31.4 N.m (2.8~3.2 kgf.m, 20.3~33.1 lb-ft) + 88°~92°

note

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Do not turn the crankshaft.

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Do not reuse the connection rod cap bolts.

(7)

Remove the connecting rod cap and lower bearing.

(8)

Measure the plastigage at its widest point.

Bearing oil clearance :

0.024 ~ 0.052 mm (0.0009 ~ 0.0020 in)

(9)

If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. Recheck the oil clearance.

note

Do not file, shim, of scrape the bearings or the caps to adjust clearance.

(10)

If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance.

note

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

note

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

(11)

Select the bearing by using selection table.

Connecting Rod Bearing Selection Table

Connecting rod bearing		Connecting rod mark
Connecting rod bearing		A(A)	B(B)	C(C)
Crank shaft pin journal mark	I(A)	A(Blue)	A(Blue)	B(Black)
	II(B)	A(Blue)	B(Black)	C(Red)
	III(C)	B(Black)	C(Red)	C(Red)

Discrimination Of Connecting Rod

Class	Mark	Connecting rod big-end inner diameter
Class	Mark	2.0L	2.2L
A	A	51.000 ~ 51.006 mm ( 2.0079 ~ 2.0081 in)	55.000 ~ 55.006 mm ( 2.1654 ~ 2.1656 in)
B	B	51.006 ~ 51.012 mm ( 2.0081 ~ 2.0083 in)	55.006 ~ 55.012 mm ( 2.1656 ~ 2.1658 in)
C	C	51.012 ~ 51.018 mm ( 2.0083 ~ 2.0086 in)	55.012 ~ 55.018 mm ( 2.1658 ~ 2.1661 in)

Discrimination Of Crankshaft Pin Journal

Class	Mark	Crankshaft pin journal outer diameter
Class	Mark	2.0L	2.2L
I	I(A)	48.012 ~ 48.018 mm (1.8902 ~ 1.8905 in)	52.012 ~ 52.018 mm (2.0477 ~ 2.0479 in)
II	II(B)	48.006 ~ 48.012 mm (1.8900 ~ 1.8902 in)	52.006 ~ 52.012 mm (2.0475 ~ 2.0477 in)
III	III(C)	48.000 ~ 48.006 mm (1.8898 ~ 1.8900 in)	52.000 ~ 52.006 mm (2.0472 ~ 2.0475 in)

Discrimination Of Connecting Rod Bearing

Class	Color	Connecting rod bearing thickness
Class	Color	Upper	Lower
A	Blue	1.472 ~ 1.477 mm ( 0.0580 ~ 0.0581 in)	1.478 ~ 1.481 mm ( 0.0582 ~ 0.0583 in)
B	Black	1.477 ~ 1.482 mm ( 0.0581 ~ 0.0583 in)	1.481 ~ 1.484 mm ( 0.0583 ~ 0.0584 in)
C	Red	1.482 ~ 1.487 mm ( 0.0583 ~ 0.0585 in)	1.484 ~ 1.487 mm ( 0.0584 ~ 0.0585 in)

Check the connecting rods.

(1)

When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.

(2)

Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.

(3)

Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.

Allowable bend of connecting rod :

0.05 mm (0.0020 in) or less / 100 mm (3.94 in)

Allowable twist of connecting rod :

0.1 mm (0.0039 in ) or less / 100 mm (3.94 in)

Clean the piston.

(1)

Using a gasket scraper, remove the carbon from the piston top.

(2)

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3)

Using solvent and a brush, thoroughly clean the piston.

note

Do not use a wire brush.

Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.

Piston-to-cylinder clearance :

0.075 ~ 0.095 mm (0.0030 ~ 0.0037 in)

(1)

Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Cylinder bore diameter

2.0L : 84.000 ~ 84.030 mm (3.3071 ~ 3.3083 in)

2.2L : 85.400 ~ 85.430 mm (3.3622 ~ 3.3634 in)

(2)

Measure the piston outside diameter at 10 mm (0.39 in) from bottom land of the piston.

Piston outside diameter

2.0L : 83.915 ~ 83.945 mm (3.3037 ~ 3.3049 in)

2.2L : 85.315 ~ 85.345 mm (3.3589 ~ 3.3600 in)

Select the piston matching with cylinder bore class.

Piston-to-cylinder clearance :

0.075 ~ 0.095 mm (0.0030 ~ 0.0037 in)

(1)

Check the cylinder bore size mark on the side of the cylinder block.

Discrimination Of Cylinder Bore

Class	Mark	Cylinder bore inner diameter
Class	Mark	2.0L	2.2L
a	A	84.000 ~ 84.010 mm (3.3071 ~ 3.3075 in)	85.400 ~ 85.410 mm (3.3622 ~ 3.3626 in)
b	B	84.010 ~ 84.020 mm (3.3075 ~ 3.3079 in)	85.410 ~ 85.420 mm (3.3626 ~ 3.3630 in)
c	C	84.020 ~ 84.030 mm (3.3079 ~ 3.3083 in)	85.420 ~ 85.430 mm (3.3630 ~ 3.3634 in)

(2)

Check the piston size mark on the piston top face.

Discrimination Of Piston

Item	Mark
1	Engine - 0 : 2.0L - 2 : 2.2L
2	Power - S : Standard - L : Low Power
3	Piston Grade - A - B - C
4	Ring- G : For General region - None : Except General

Discrimination Of Piston Outer Diameter

Class	Mark	Piston outer diameter
Class	Mark	2.0L	2.2L
A	A	83.915 ~ 83.925 mm (3.3037 ~ 3.3041 in)	85.315 ~ 85.325 mm (3.3626 ~ 3.3630 in)
B	B	83.925 ~ 83.935 mm (3.3041 ~ 3.3045 in)	85.325 ~ 85.335 mm (3.3630 ~ 3.3596 in)
C	C	83.935 ~ 83.945 mm (3.3045 ~ 3.3049 in)	85.335 ~ 85.345 mm (3.3596 ~ 3.3600 in)

Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.

Piston ring side clearance

No.1 : 0.102 ~ 0.146 mm (0.0040 ~ 0.0057 in)

No.2 : 0.070 ~ 0.110 mm (0.0028 ~ 0.0043 in)

Oil ring : 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)

If the clearance is greater than maximum, replace the piston.

Inspect the piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.

Piston ring end gap

No.1 : 0.18 ~ 0.33 mm (0.0071 ~ 0.0130 in)

No.2 : 0.35 ~ 0.50 mm (0.0138 ~ 0.0297 in)

Oil ring : 0.25 ~ 0.50 mm (0.0098 ~ 0.0197 in)

If the gap exceeds the specifications, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is over the specifications, the cylinder block must be rebored.

Measure the outer diameter of piston pin.

Piston pin diameter :

33.991 ~ 33.997 mm (1.3382 ~ 1.3385 in)

Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :

0.007 ~ 0.019 mm (0.0003 ~ 0.0007 in)

Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.

Piston pin-to-connecting rod interference :

0.023 ~ 0.041 mm (0.0009 ~ 0.0016 in)

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Thoroughly clean all parts to assembled.

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Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.

Assemble the piston and the connecting rod.

(1)

Install the snap ring in one side of the piston pin hole.

(2)

Align the piston front mark and the connecting rod front mark.

(3)

Insert the piston pin into the piston pin hole and the small end bore of connecting rod.

(4)

Install the snap ring in the other side after inserting the piston pin.

note

Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the connecting rod before inserting the piston pin.

note

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Be careful not to damage and scratch the small end bore, piston pin hole and piston pin when inserting the piston pin.

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Set the snap ring firmly so that the snap ring can contact with the whole groove of the piston pin hole.

Assemble the piston rings.

(1)

Install the oil ring with the coil spring by hand.

(2)

Using a piston ring expander, install the 2 compression rings with the maker mark facing upward.

(3)

Position the piston rings so that the ring ends are as shown.

(The No.1 ring should be on the opposite side of the No.2 ring and the oil ring should be on the opposite side of the coil spring.) Example)

Example)

Assemble the connecting rod bearings.

(1)

Align the bearing claw with the groove of the connecting rod or connecting rod cap and install the bearings (A) in the connecting rod and connecting rod cap (B).

(2)

Apply a coat of engine oil after assembling the bearings.

Assemble the piston and connecting rod assemblies.

note

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Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.

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Install the piston and connecting rod assembly with the front marks facing the front of the engine.

(1)

Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.

(2)

Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.

(3)

Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.

Tightening torque :

27.5~31.4 N.m (2.8~3.2 kgf.m, 20.3~33.1 lb-ft) + 88°~92°

Using the SST (09221-4A000) (A), tighten the connecting rod cap bolts.

note

Do not reuse the connecting rod cap bolts.

Check the side clearance between piston and connecting rod.

Assemble the other parts in the reverse order of disassembly.