ACURA RL KA9 1996 Service Repair Manual

Pistons
Inspectio n
1. Chec k th e pisto n fo r distortio n o r cracks .
2. Measur e th e pisto n diamete r a t a poin t 14. 0 m m
(0.5 5 in ) fro m th e botto m of th e skirt .
NOTE : Ther e ar e tw o standard-siz e piston s (N o let -
te r o r A , an d B) . Th e lette r i s stampe d o n th e to p o f
th e piston . Letter s ar e als o stampe d o n th e cylinde r
bloc k a s cylinde r bor e sizes .
Standar d Pisto n Diamete r
Oversiz e Pisto n Diamete r
0.25 : 90.23 0 - 90.24 0 m m (3.552 4 - 3.552 7 in )
0.50 : 90.48 0 - 90.49 0 m m (3.562 2 - 3.562 6 in )
SKIR T DIAMETE R14.0 mm(0.5 5 in)
89.98 0 - 89.99 0 m m
(3.542 5 - 3.542 9 in )
89.97 0 - 89.98 0 m m
(3.5421 - 3.542 5 in )
B
No Lette r
(A)
89.97 0 m m
(3.542 1 in )
Servic
e Limi t
89.96 0 m m
(3.541 7 in ) 3
. Calculat e th e differenc e betwee n cylinde r bor e diame -
te r (se e pag e 7-15 ) an d pisto n diameter .
Piston-to-Bloc k Clearanc e
Standar d (New) : 0.0 2 - 0.0 4 m m
(0.00 1 - 0.00 2 in )
Servic e Limit : 0.0 8 m m (0.00 3 in )
SERVIC E LIMI T0.08 m m (0.00 3 in )
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Cylinder Bloc k
Inspectio n
1. Measur e wea r an d tape r i n direction s X an d Y at
thre e level s i n eac h cylinde r a s shown .
CYLINDE R BOR E SIZE S ( A o r I , B or Il )NOTE : T o maintai n prope r pisto n
clearance , matc h thes e letter s wit h
the letter s o n th e pistons . Th e let -ters o n th e bloc k rea d fro m fron t t orear . No . 1 throug h No . 3 cylinder son th e firs t line , an d No . 4 throug hNo. 6 cylinder s o n th e secon d line .
CYLINDE RBOREGAUG E
Cylinde r Bor e Siz e
Standar d (New ) Service Limi t
90.07 0 m m
(3.546 1 in )
90.07 0 m m
(3.546 1 in )
90.01
0 - 90.02 0 m m
(3.543 7 - 3.544 1 in )
90.00 0 - 90.01 0 m m
(3.543 3 - 3.543 7 in )
B o r Il
A o r I
Oversiz e
0.25: 90.25 0 - 90.27 0 m m (3.553 1 - 3.553 9 in )
0.50 : 90.50 0 - 90.52 0 m m (3.563 0 - 3.563 8 in )
Bor e Tape r
Limit : (Differenc e betwee n firs t an d thir d measure -
ment ) 0.0 5 m m (0.00 2 in )
Reborin g Limit : 0. 5 m m (0.0 2 in )
• I f measurement s i n an y cylinde r ar e beyon d th e
oversiz e bor e servic e limit , replac e th e cylinde r
block.
• I f th e bloc k i s t o b e rebored , refe r t o Pisto n Clear -
anc e Inspectio n (se e pag e 7-14 ) afte r reboring .
NOTE : Score d o r scratche d cylinde r bore s mus t b e
honed .
2 . Chec k th e to p o f th e cylinde r bloc k fo r warpage .
Measur e alon g th e edge s an d acros s th e cente r a s
shown .
SURFACE S T O B E MEASURE D
Cylinder Bloc k Warpage :
Standar d (New) : 0.0 7 m m (0.00 3 in ) max .
Servic e Limit : 0.1 0 m m (0.00 4 in )
PRECISIO N STRAIGH T EDG E
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Cylinder Bloc k
Bore Honin g
1. Measur e th e cylinde r bore s a s show n o n pag e 7-15 .
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 .
2 . 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 a 40 0 gri t o r fine r
stone , 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 .
3 . 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 .
4 . 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 if 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:
• Afte r honing , clea n th e cylinde r thoroughl y wit h
ho t soap y water .
• Onl y score d o r scratche d cylinde r bore s mus t b e
honed .
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Piston Pins

Removal

1. Apply engine oil to the piston pin snap rings, and

turn them in the ring grooves until the end gaps are

lined up with the cutouts in the piston pin bores.

NOTE: Take care not to damage the ring grooves.

SNAP RING

Cutout in the

piston pin bore

2. Remove both snap rings. Start at the cutout in the

piston pin bore.

NOTE: Remove the snap rings carefully so they do

not go flying or get lost. Wear eye protection.

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3. Hea t th e pisto n an d connectin g ro d assembl y t o
approximatel y 158° F (70°C) , the n remov e th e pisto n
pin.
Wor k carefull y t o preven t gettin g
burned .
NOTE : Inspec t th e piston , pisto n pi n an d connectin g
ro d whe n the y ar e a t th e roo m temperature .
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Connecting Rod s
Selectio n
Each ro d fall s int o on e o f fou r toleranc e range s (fro m 0 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 or 4/I , Il, IIl o r
IIIl) indicatin g th e range . Yo u ma y fin d an y combinatio n
of 1 , 2 , 3 or 4/I , Il, IIl o r IIIl i n an y engine .
Normal 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
an d d o no t indicat e th e positio n of the ro d i n th e
engine .
• Inspec t 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 .
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Piston Pin s
Inspectio n
NOTE: Inspec t th e piston , pisto n pi n an d connectin g ro d
whe n the y ar e a t roo m temperature .
1 . Measur e th e diamete r o f th e pisto n pin .
Pisto n Pi n Diameter :
Standar d (New) : 21.96 1 - 21.96 5 m m
(0.864 6 - 0.864 8 in )
Servic e Limit : 21.95 3 m m (0.864 3 in )
2 . Zer o th e dia l indicato r t o th e pisto n pi n diameter . 4
. Measur e th e pisto n pin-to-connectin g ro d clearance .
Pisto n Pin-to-Connectin g Ro d Clearance :
Standar d (New) : 0.00 5 - 0.01 5 m m
(0.000 2 - 0.000 6 in )
Servic e Limit : 0.0 2 m m (0.000 8 in )
3
. Chec k th e differenc e betwee n th e pisto n pi n diame -
te r an d pisto n pi n hol e diamete r o n th e piston .
NOTE : Chec k th e pisto n fo r distortio n o r cracks .
Pisto n Pin-to-Pisto n Clearance :
Standar d (New) : -0.00 5 t o +0.00 2 m m
(-0.000 2 t o +0.000 1 in )
Servic e Limit : 0.00 5 m m (0.000 2 in )
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4. Instal l th e remainin g sna p ring .
CONNECTIN GROD
Installatio n
1. Instal l a pisto n pi n sna p ring .
SNA P RIN G
3. Coa t th e pisto n pi n bor e in th e piston , th e bor e in th e
connectin g rod , an d th e pisto n pi n wit h engin e oil .
Instal l th e pisto n pin .
NOTE : Instal l th e pisto n wit h it s offse t mar k an d th e
oi l hol e in th e connectin g ro d o n th e sam e side .
OFFSE TMARK
OIL HOL E
The arro w mus t fac e th e
timin g bel t sid e o f th e
engin e an d th e connectin g
ro d oi l hol e mus t fac e th e
righ t sid e o f th e engine .
Assembl e th e ro d an d th e
pisto n wit h th e off-se t
mar k an d oi l hol e o n th e
sam e side .
PISTO N
PISTON PI N
2. Hea t th e pisto n to approximatel y 158° F (70°C) .
Wor k carefull y t o preven t gettin g
burned.
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*1: RIKE N manufacture d pisto n ring .
*2 : TEIKOK U PISTO N RIN G manufacture d pisto n ring .
PISTO N RIN G
END GA P
15 - 2 0 m m(0.6-0. 8 in )
Pisto n Ring s
End Ga p
1. Usin g a piston , pus h a ne w rin g int o th e cylinde r
bore 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 :
• I f th e ga p is to o small , chec k t o 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 7-15 .
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
(0.01 0 - 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
(0.01 6 - 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 )
Replacemen t
1. Usin g a rin g expander , remov e th e ol d pisto n rings .
2 . Clea n al l th e rin g groove s thoroughly .
NOTE:
• Us e a squared-of f broke n rin g o r rin g groov e
cleane r wit h a blad e t o fi t th e pisto n grooves . Fil e
dow n th e blad e i f necessary .
• To p rin g groov e i s 1. 5 m m (0.0 6 in ) wide , th e
secon d rin g groov e i s 1. 2 m m (0.0 5 in ) wide , an d
th e oi l rin g groov e is 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 i s 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 th e prope r sequenc e an d posi -
tio n (se e page s 7-21 , 7-22 ).
NOTE : D o no t reus e ol d pisto n rings .
PISTO N RIN G
RING EXPANDE R(Commerciall y available )
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Ring-to-Groove Clearance

After installing a new set of rings, measure the ring-to-

groove clearance:

Top Ring Clearance

Standard (New): 0.055 - 0.080 mm

(0.0022 - 0.0031 in)

Service Limit: 0.13 mm (0.005 in)

Second Ring Clearance

Standard (New): 0.030 - 0.055 mm

(0.0012 - 0.0022 in)

Service Limit: 0.13 mm (0.005 in)

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