Inspection After Disassembly
CRANKSHAFT SIDE CLEARANCE
Using a dial gauge, measure the clearance between the thrust bearings and the crankshaft arm when the crankshaft is moved fully forward or backward.
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit : 0.30 mm (0.0118 inch)
If the measured value exceeds the limit, replace the thrust bearings, and measure again. If it still exceeds the limit, replace the crankshaft also.
CONNECTING ROD SIDE CLEARANCE
Measure side clearance between connecting rod and crankshaft arm with feeler gauge.
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit : 0.40 mm (0.016 inch)
If the measured value exceeds the limit, replace the connecting rod, and measure again. If it still exceeds the limit, replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
Measure the inner diameter of piston pin bore with an inside micrometer.
Standard : 21.993 - 22.005 mm (0.8659 - 0.8663 inch)
Outer Diameter of Piston Pin
Measure outer diameter of piston pin with a micrometer.
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 inch)
Piston and Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) - (Outer diameter of piston pin)
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 inch)
If clearance exceeds specification, replace piston/piston pin assembly with reference to specification of each parts.
When replacing piston/piston pin assembly, refer to "PISTON TO CYLINDER BORE CLEARANCE".
PISTON RING SIDE CLEARANCE
Measure side clearance of piston ring and piston ring groove with feeler gauge.
Standard:
Top ring: 0.045 - 0.080 mm (0.0016 - 0.0031 inch)
2nd ring: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Oil ring: 0.065 - 0.135 mm (0.0026 - 0.0053 inch)
Limit:
Top ring: 0.11 mm (0.0043 inch)
2nd ring: 0.1 mm (0.004 inch)
If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
Check if inner diameter of cylinder bore is within specification. Insert piston ring until middle of cylinder with piston, and measure gap.
Standard:
Top ring: 0.23 - 0.33 mm (0.0091 - 0.0130 inch)
2nd ring: 0.33 - 0.48 mm (0.0130 - 0.0189 inch)
Oil ring: 0.20 - 0.50 mm (0.0079 - 0.0197 inch)
Limit:
Top ring: 0.54 mm (0.0213 inch)
2nd ring: 0.80 mm (0.0315 inch)
Oil ring: 0.95 mm (0.0374 inch)
If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.
CONNECTING ROD BEND AND TORSION
Check with connecting rod aligner.
Bend:
Limit: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) length
Torsion:
Limit: 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length
If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)
Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod bolt to the specified torque, measure the connecting rod big end inner diameter using an inside micrometer.
Standard: 55.000 - 55.013 mm (2.1654 - 2.1659 inch)
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
Measure inner diameter of bushing.
Standard: 22.000 - 22.012 mm (0.8661 - 0.8666 inch)
Outer Diameter of Piston Pin
Measure outer diameter of piston pin.
Standard: 21.989 - 22.001 mm (0.8657 - 0.8662 inch)
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) - (Outer diameter of piston pin)
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
Limit: 0.030 mm (0.0012 inch)
If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
If replacing the piston and piston pin assembly, refer to "PISTON TO CYLINDER BORE CLEARANCE".
If replacing the connecting rod assembly, refer to "OIL CLEARANCE OF CONNECTING ROD BEARING".
Factory installed parts grading:
Service parts apply only to grade 0.
CYLINDER BLOCK DISTORTION
GUsing a scraper, remove gasket on the cylinder block surface, and also remove oil, scale, carbon, or other contamination.
CAUTION: Be careful not to allow gasket flakes to enter the oil or coolant passages.
Measure the distortion on the block upper face at some different points in 6 directions.
Limit : 0.1 mm (0.004 inch)
If out of the distortion limit, replace the cylinder block.
INNER DIAMETER OF MAIN BEARING HOUSING
Install the main bearing caps and main bearing beam with the main bearings removed, and tighten the mounting bolts to the specified torque.
Using a bore gauge, measure the inner diameter of the main bearing housing.
Standard: 63.993 - 64.017 mm (2.5194 - 2.5203 inch)
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at 6 different points on each cylinder. (X and Y directions at A, B and C) (Y is in longitudinal direction of engine)
Standard inner diameter: 95.500 - 95.530 mm (3.7598 - 3.7610 inch)
Wear limit: 0.2 mm (0.008 inch)
Out-of-round (Difference between X and Y): 0.015 mm (0.0006 inch)
Taper limit (Difference between A and C): 0.01 mm (0.0004 inch)
If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or rebore the inner wall.
An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard.
Oversize (OS): 0.2 mm (0.008 inch)
Outer Diameter of Piston
Measure piston skirt outer diameter using micrometer.
Measure point: Distance from the top 41.0 mm (1.614 inch)
Standard: 95.480 - 95.510 mm (3.7590 - 3.7602 inch)
Piston-to-Cylinder Bore Clearance
Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B). (Clearance) = (Inner diameter of cylinder) - (Outer diameter of piston skirt).
Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
Limit: 0.08 mm (0.0031 inch)
If it exceeds the limit, replace piston/piston pin assembly. Refer to "HOW TO SELECT PISTON".
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-cylinder bore clearance to piston diameter "A".
Rebored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 inch)
2. Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores.
- When any cylinder needs boring, all other cylinders must also be bored.
- Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 inch) or so in diameter at a time.
4. Hone cylinders to obtain specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
Measurement should be done after cylinder bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
Measure outer diameter of crankshaft journals.
Standard: 59.951 - 59.975 mm (2.3603 - 2.3612 inch) dia.
OUTER DIAMETER OF CRANKSHAFT PIN
Measure outer diameter of crankshaft pin.
Standard: 51.956 - 51.974 mm (2.0455 - 2.0462 inch) dia.
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
Using a micrometer, measure the dimensions at 4 different points shown in the figure on each journal and pin.
Out-of-round is indicated by the difference in dimensions between X and Y at A and B.
Taper is indicated by the difference in dimension between A and B at X and Y.
Limit:
Out-of-round (X- Y):.0.002 mm (0.0001 inch)
Taper (A - B): 0.002 mm (0.0001 inch)
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on the both end of the crankshaft.
Place a dial gauge straight up on the No. 3 journal.
While rotating the crankshaft, read the movement of the pointer on the dial gauge. (Total indicator reading)
Standard: Less than 0.025 mm (0.0010 inch)
Limit: 0.10 mm (0.004 inch)
OIL CLEARANCE OF CONNECTING ROD BEARING
Method by Calculation
Install the connecting rod bearings to the connecting rod and the cap, and tighten the connecting rod bolts to the specified torque. Using a inside micrometer measure the inner diameter of connecting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) - (Outer diameter of crankshaft pin)
Standard: 0.034 - 0.059 mm (0.0014 - 0.0018 inch) (actual clearance)
Limit: 0.070 mm (0.0026 inch)
If clearance cannot be adjusted within the standard, grind crankshaft pin and use undersized bearing.
Method of Using Plastigage
Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod bolts to the specified torque.
CAUTION: Never rotate the crankshaft.
Remove the connecting rod cap and bearings, and using the scale on the plastigage bag, measure the plastigage width.
NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".
OIL CLEARANCE OF MAIN BEARING
Method by Calculation
Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter with the bearing cap bolt tightened with main bearing beam to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal)
Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 inch) (actual clearance)
Limit: 0.065 mm (0.0026 inch)
If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the standard.
Method of Using Plastigage
Remove oil and dust on the crankshaft journal and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
Tighten the main bearing bolts with main bearing beam to the specified torque.
CAUTION: Never rotate the crankshaft.
Remove the bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width.
NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".
CRUSH HEIGHT OF MAIN BEARING
When the bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude.
Standard: There must be crush height
If the standard is not met, replace main bearings.
OUTER DIAMETER OF MAIN BEARING CAP BOLT
Measure outer diameters (d1, d2) at two positions shown in the figure.
Measure d2 at a point within block A.
Limit: 0.11 mm (0.0051 inch)
When the value of d1- d2 exceeds the limit (a large difference in dimensions), replace the bolt with a new one.
OUTER DIAMETER OF CONNECTING ROD BOLT
Measure outer diameter "d" at position shown in the figure.
Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit: 7.75 mm (0.3051 inch)
When "d" exceeds the limit (when it becomes thinner), replace the bolt with a new one.
SIGNAL PLATE
Check the drive plate and signal plate for deformation or cracks.
OIL JET
Check nozzle for deformation and damage.
Blow compressed air from nozzle, and check for clogs.
If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE
Using a clean plastic stick, press check valve in oil jet relief valve. Make sure that valve moves smoothly with proper reaction force.
If it is not satisfied, replace oil jet relief valve.