ACURA TL 1995 Service Repair Manual

Cylinder Bloc k Piston Pin s
Bor e Honin g
2.
3.
4 .
Measur e th e cylinde r bore s a s show n o n pag e 7-13 .
I f th e cylinde r bloc k i s t o b e reused , hon e th e cylin -
der s an d remeasur e th e bores .
Hon e th e cylinde r bore s wit h honin g oi l an d a fin e
(40 0 grit ) ston e in a 60 degre e crosshatc h pattern .
NOTE:
• Us e onl y a rigi d hon e wit h 40 0 gri t o r fine r ston e
suc h a s Sunnen , Ammco , o r equivalent .
• D o no t us e stone s tha t ar e wor n o r broken .
Whe n honin g i s complete , thoroughl y clea n th e
cylinde r bloc k o f al l meta l particles . Was h th e cylin -
de r bore s wit h ho t soap y water , the n dr y an d oi l
the m immediatel y t o preven t rusting .
NOTE : Neve r us e solvent , i t wil l onl y redistribut e
th e gri t o n th e cylinde r walls .
I f scorin g o r scratche s ar e stil l presen t i n th e cylin -
de r bore s afte r honin g t o th e servic e limit , rebor e
th e cylinde r block .
NOTE : Som e ligh t vertica l scorin g an d scratchin g is
acceptabl e i f i t i s no t dee p enoug h t o catc h you r fin -
gernai l an d doe s no t ru n th e ful l lengt h o f th e bore .
CYLINDE R BLOC KCYLINDE R HON E(Commerciall y available )
NOTE:
After honing , clea n th e cylinde r thoroughl y wit h
soap y water .
Onl y score d o r scratche d cylinde r bore s mus t b e
honed .
Remova l
1. Assembl e th e specia l too l a s shown .
PISTON BAS E HEA D07HAF-PL2010 2
PISTON PI N BAS E INSER T07GAF-PH60300
PISTO N BAS E07973-657050 0 PISTO N BAS E SPRIN G07973-6570600
2 . Adjus t th e lengt h o f th e pisto n pi n drive r t o 52. 5 m m
(2.0 7 in ) a s shown .
PISTON PI N DRIVE R HEA D07973-PE0032 0
PISTON PI N DRIVE RSHAFT07973-PE0031 0
PILOT COLLA R07GAF-PH7010 0Embossed mar kfacin g up .
NOTE : Us e hydrauli c press .When pressin g pi n i n o r out ,mak e sur e tha t th e recesse dportion o f th e pisto n align swith th e lip s o n th e collar .
3. Plac e th e pisto n o n th e pisto n bas e an d pres s th e pi n
ou t wit h a hydrauli c press .
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Connecting Rod s
Piston Pin s
Selectio n
Installation
Each ro d fall s int o on e o f fou r toleranc e range s (fro m O to
0.02 4 m m (0.000 9 in) , i n 0.00 6 m m (0.000 2 in ) increments )
dependin g o n th e siz e o f it s bi g en d bore .
It's the n stampe d wit h a numbe r (1 , 2 , 3 o r 4/I , o r
indicatin g th e range . Yo u ma y fin d an y combinatio n
of 1 , 2 , 3 or 4/I , i n an y engine .
Norma l Bor e Size : 57. 0 m m (2.2 4 in )
NOTE :
Referenc e number s o r bar s ar e fo r bi g en d bor e siz e
and d o no t indicat e th e positio n o f th e ro d i n th e
engine .
Inspect eac h connectin g ro d fo r crack s an d hea t dam -
age.
CONNECTIN G RO D BOR EREFERENC E NUMBE R o r BA RHalf o f numbe r i s stampe d o nbearin g cap , th e othe r hal f o nconnectin g rod .
Inspec t bolt s
an d nut s fo r
stres s cracks .
1. Us e a hydrauli c pres s fo r installation .
Whe n pressin g th e pi n i n o r out , b e sur e t o posi -
tio n th e recesse d fla t o n th e pisto n agains t th e
lug s o n th e pisto n bas e head .
The arro w mus t fac e th etimin g bel t sid e o f th eengin e an d th e connectin grod oi l hol e mus t fac e th erigh t sid e o f th e engine .
Assembl e th e ro d an d th episto n wit h th e off-se tmark an d oi l hol e o n th esam e side .OFFSE TMARK
OIL HOL E
PISTO N PI N DRIVE R HEA D07973 - PE0032 0
52.5 mm(2.0 7 in)
Embosse d mar kfacin g up .
Adjus t th e lengt h o f th episto n pi n drive r t o52. 5 mm (2.0 7 in)
PISTO N PI N DRIVE R SHAF T07973 - PE0031 0
PISTON PI N
PILO T COLLA R07GAF-PH7010 0
PISTON PI N BAS E INSER T07GAF-PH6030 0
PISTON BAS E HEA D07HAF-PL2010 2
NOTE: Us e a hydrauli c press . Whe n pressin g th e pi n
i n o r out , mak e sur e tha t th e recesse d portio n o f th e
pisto n align s wit h th e lug s o n th e pisto n bas e head .
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Piston Pins

Inspection

1. Measure the diameter of the piston pin.

Piston Pin Diameter:

Standard (New): 21.994 - 22.000 mm

(0.8659 - 0.8661 in)

Oversize: 21.997 - 22.003 mm

(0.8660 - 0.8663 in)

NOTE: All replacement piston pins are oversize.

2. Zero the dial indicator to the piston pin diameter.
3. Measure the piston pin-to-piston clearance.

NOTE: Check the piston for distortion or cracks.

If the piston pin clearance is greater then 0.024 mm

(0.0009 in), remeasure using an oversize piston pin.

Piston Pin-to-Piston Clearance:

Standard (New): 0.010 - 0.019 mm

(0.0004 - 0.0007 in)

4. Check the difference between the piston pin diame-

ter and connecting rod small end diameter.

Piston Pin-to-Connecting Rod Interference:

Standard (New): 0.013 - 0.032 mm

(0.0005 - 0.0013 in)ProCarManuals.com

Piston Ring s
End Ga pReplacemen t
1. Usin g a piston , pus h a ne w rin g int o th e cylinde r
bor e 15-2 0 m m (0. 6 - 0. 8 in ) fro m th e bottom .
2 . Measur e th e pisto n rin g end-ga p wit h a feele r
gauge:
If th e ga p is to o small , chec k to se e if yo u hav e th e
prope r ring s fo r you r engine .
I f th e ga p i s to o large , rechec k th e cylinde r bor e
diamete r agains t th e wea r limit s o n pag e 7-13 .
I f th e bor e i s ove r th e servic e limit , th e cylinde r
bloc k mus t b e rebored .
Pisto n Rin g End-Gap :
To p Rin g
Standar d (New) : 0.2 5 - 0.4 0 m m
(0.010-0.01 6 in )
Servic e Limit : 0.7 0 m m (0.02 8 in )
Secon d Rin g
Standar d (New) : 0.4 0 - 0.5 5 m m
(0.016-0.02 2 in )
Servic e Limit : 0.8 5 m m (0.03 3 in )
Oi l Rin g
Standar d (New) : 0.2 0 - 0.7 0 m m
(0.00 8 - 0.02 8 in ) * 1
0.2 0 - 0.5 0 mm
(0.00 8 - 0.02 0 in ) * 2
Servic e Limit : 0.8 0 m m (0.03 1 in )
*1 : RIKE N manufacture d pisto n ring .
*2 : TEIKOK U PISTO N RIN G manufacture d pisto n ring . 1
. Usin g a rin g expander , remov e th e ol d pisto n rings .
2 . Clea n al l rin g groove s thoroughly .
NOTE:
Use a squared-of f broke n rin g o r rin g groov e
cleane r wit h blad e t o fi t th e pisto n grooves . Fil e
dow n blad e if necessary .
To p an d 2n d rin g groove s ar e 1. 2 m m (0.0 5 in )
wid e an d oi l rin g groov e i s 2. 8 m m (0.1 1 in )
wide .
CAUTION : D o no t us e a wir e brus h to clea n th e rin g
grooves , o r cu t rin g groove s deepe r wit h th e clean -
in g tool .
NOTE : I f th e pisto n is t o b e separate d fro m th e con -
nectin g rod , d o no t instal l ne w ring s yet .
3 . Instal l ne w ring s i n prope r sequenc e an d positio n
(page 7-18 ).
NOTE : D o no t reus e ol d pisto n rings .
PISTO N RIN G
RING EXPANDE R(Commerciall y available )
PISTO N RIN G
END GA P
15 - 2 0 m m(0.6 -0. 8 in)
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Piston Ring s
Ring-to-Groov e Clearanc e
After installin g a ne w se t o f rings , measur e th e ring-to -
groov e clearance :
To p Rin g Clearanc e
Standar d (New) : 0.05 5 - 0.08 0 m m
(0.002 2 - 0.003 1 in )
Servic e Limit : 0.1 3 m m (0.00 5 in )
Secon d Rin g Clearanc e
Standar d (New) : 0.03 0 - 0.05 5 m m
(0.001 2 - 0.002 2 in )
Servic e Limit : 0.1 3 m m (0.00 5 in )
FEELE R GAUG E
Alignmen t
1. Instal l th e ring s a s show n o n pag e 7-17 .
Identif y th e to p an d secon d ring s b y th e chamfe r o n
th e edge . Mak e sur e the y ar e in th e prope r groove s o n
th e piston .
NOTE : Th e manufacturin g mark s mus t b e facin g
upward .
TOP RIN G
SECON D RIN G
MAR K
TOP RIN G
SECON D RIN GMAR K
SPACE R
2. Rotat e th e ring s i n th e groove s t o mak e sur e the y d o
no t bind .
3. Positio n th e rin g en d gap s a s shown :
SECON D RIN G GA P D
O NO T positio n an y rin g ga p
a t pisto n thrus t surfaces .
OI L RIN G
GAP
TOP RIN G GA P
DO NO T positio n an y rin g ga pin lin e wit h pisto n pi n hole .
SPACE R GA P
OIL RIN GGAP
OIL RIN G
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Pistons

Installation

Before installing the piston, apply a coat of engine

oil to the ring grooves and cylinder bores.

1. If the crankshaft is already installed:

Guide the piston carefully to prevent damage.

Fit long rubber hoses (about 30 cm (12 in) long) to

the connecting rod bolts to protect the crankshaft.

Install the pistons after setting the crankshaft to

BDC for each cylinder.

INCORRECT

CORRECT

RUBBER HOSES

Remove the connecting rod caps, then slip the

long rubber hoses over the threaded ends of the

connecting rod bolts.

Install the ring compressor, check that the bear-

ing is securely in place; then position the piston

in the cylinder and tap it in using the wooden

handle of a hammer.

Stop after the ring compressor pops free, and

check the connecting rod-to-crank journal align-

ment before pushing the piston into place.

Install the rod caps with bearings, and torque the

nuts to 44 N-m (4.5 kgf-m, 33 Ibf-ft).
2. If the crankshaft is not installed:

Remove the rod caps and bearings, install the

ring compressor, then position the piston in the

cylinder and tap it in using the wooden handle of

a hammer.

The arrow must face

the timing belt side

of the engine and the

connecting rod oil hole

must face the right side

of the engine.

CONNECTING ROD

OIL HOLE

RUBBER

HOSE

NOTE: Maintain downward force on the ring com-

pressor to prevent rings from expanding before

entering the cylinder bore.

Use the wooden handle

of a hammer to push, or

tap the piston into the

cylinder bore.

RING COMPRESSOR

(Commercially available)ProCarManuals.com

Crankshaft Oi l Sea l
Installatio n
The sea l surfac e o n th e bloc k shoul d b e dry .
Appl y a ligh t coa t o f oi l t o th e crankshaf t an d t o
th e li p o f th e oi l seal .
1 . Usin g th e specia l tool , driv e th e crankshaf t oi l sea l
int o th e rea r cover .
REAR COVE R
DRIVE R
07749-001000 0
DRIVER Instal l oi l sea l wit h th eATTACHMEN T par t numbe r sid e07948-SB0010 1 facing out .
2. Confir m tha t th e clearanc e i s equa l al l th e wa y
aroun d wit h a feele r gauge .
Clearance : 0. 2 - 0. 5 m m (0.0 1 - 0.0 2 in )
0.2 — 0.5 m m(0.0 1 — 0.02 in)
REA RCOVE R
REAR COVE R CRANKSHAF
T OI L
SEA L
NOTE : Refe r t o page s 7-2 5 an d 8-1 2 fo r installatio n
of th e oi l pum p sid e oi l seal .
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Crankshaft

Installation

Before installing the crankshaft, apply a coat of

engine oil to the main bearings and rod bearings.

1. Insert the bearing halves in the cylinder block and

connecting rods.

2. Lower the crankshaft into the block.

3. Install the thrust washers on the No. 4 journal. Oil

the thrust washer surfaces.

THRUST WASHERS

Grooved sides face

outward.ProCarManuals.com

4. Instal l th e bearing s an d caps . Torqu e th e ca p bolts .
BEARIN G CAP S
TIMIN G BEL TSIDE
CA P BOL T
9 x 1.2 5 mm39 N- m (4. 0 kgf-m ,
2 9 Ibf-ft )
RUBBE R
CAP
JOURNA L NUMBE R
CAP BOLT S11 x 1. 5 m m76 N- m (7. 8 kgf-m ,
5 6 Ibf-ft )
BEARIN G CA P
MAIN BEARIN G
SIDE CA P BOL T10 x 1.2 5 mm49 N- m (5. 0 kgf-m ,
3 6 Ibf-ft ) SHOR
T
LON G BOLT S
BOL T
5. Chec k th e connectin g ro d bearin g clearanc e wit h
plastigag e (se e pag e 7-7 ), the n torqu e th e connect -
in g ro d ca p nuts .
NOTE : Referenc e number s o n th e connectin g rod s
ar e fo r big-en d bor e toleranc e an d d o NO T indicat e
th e positio n o f th e pisto n i n th e engine .
9 x 0.7 5 mm44 N- m (4. 5 kgf-m ,
3 3 Ibf-ft )
• Lin e u p th e mar k whe ninstallin g th e connectin grod cap .
LON GBOLT
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Crankshaft

BEARING CAP BOLTS TORQUE SEQUENCE

CAUTION: Whenever any crankshaft bearing or con-

necting rod bearing is replaced, it is necessary after

reassembly to run the engine at idling speed until it

reaches normal operating temperature, then contin-

ue to run it for approximately 15 minutes.
9. Apply liquid gasket to the cylinder block mating sur-

face of the rear cover, then install it on the cylinder

block.

REAR COVER

Apply liquid gasket

along the broken line.

Do not apply liquid gasket

to O-ring groove.

NOTE:

Use liquid gasket, Part No. 08718 - 0001 or 08718

- 0003.

Check that the mating surfaces are clean and dry

before applying liquid gasket.

Apply liquid gasket evenly, being careful to cover

all the mating surface.

To prevent oil leakage, apply liquid gasket to the

inner threads of the bolt holes.

Do not apply liquid gasket to O-ring grooves.

Do not install the parts if five minutes or more

have elapsed since applying liquid gasket.

Instead reapply liquid gasket after removing old

residue.

After assembly, wait at least 30 minutes before

filling the engine with oil.
Installation (cont'd)

6. Tighten the 9 x 1.25 mm cap bolts to the specified

torque.

Torque: 39 N-m (4.0 kgf-m, 29 Ibf-ft)

7. Tighten the 11 x 1.5 mm cap bolts to the specified

torque.

Torque: 76 N-m (7.8 kgf-m, 56 Ibf-ft)

8. Tighten the 10 x 1.25 mm cap side bolts to the spec-

ified torque.

Torque: 49 N-m (5.0 kgf-m, 36 Ibf-ft)

Coat the bolt thread and seat surfaces with engine

oil.

9 x
1.25
mm

39 N-m (4.0 kgf-m,

29 Ibf-ft)
11 x 1.5 mm

76 N-m (7.8 kgf-m,

56 Ibf-ft)

10 x
1.25
mm

49 N-m (5.0 kgf-m,

36 Ibf-ft)ProCarManuals.com