Crankshaft and Cylinder Block Inspection
INSPECTIONCRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIC GAUGING MATERIAL METHOD)
1. Remove oil from the crankshaft journal and crankshaft bearing.
2. Install the crankshaft.
3. Cut plastic gauging material to the same length as the width of the bearing and place it on the journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the plastic gauging material at its widest part by using a scale printed on the plastic gauging material package.
Standard value: 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
Limit: 0.1 mm (0.003 inch)
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable limit or replace.
Grinding limit: 0.2 mm (0.008 inch)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new): 210.5 mm (8.29 inches)
4. Check the cylinder walls for scratches and seizure. If defects are evident, replace or bore to oversize and replace pistons and piston rings.
5. Using a cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct by boring the cylinders to an oversize and replace pistons and piston rings. Measure at the points shown in the illustration. Standard value:
Cylinder Inside Diameter: 91.1 mm (3.59 inches)
Cylindricity: 0.01 mm (0.0003 inch)
BORING CYLINDER
1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder.
Piston size identification
NOTE: Size mark is stamped on the piston top.
2. Measure the outside diameter of the piston to be used. Measure it in the thrust direction as shown.
3. Based on the measured piston Outside Diameter (OD), calculate the boring finish dimension. Boring finish dimension =
Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin)
CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders in the order of number 2, number 4, number 6, number 1, number 3 and number 5.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
NOTE: When boring cylinders, finish all of six cylinders to the same oversize. Do not bore only one cylinder to an oversee.