Cylinder Block Assembly: Testing and Inspection
Inspection
Connecting Rod And Crankshaft
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth.
Specification
Standard : 0.1 - 0.25mm(0.0039 - 0.0098in.)
Limit : 0.4mm(0.0157in.)
A. If out-of-tolerance, install a new connecting rod.
B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check that the matchmarks 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 the lower bearing.
(4) Clean the crankshaft pin journal and the bearing.
(5) Place a plastic gage across the crankshaft pin.
(6) Reinstall the lower bearing and the connecting rod cap and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90°
NOTE:
Do not turn the crankshaft.
(7) Remove the connecting rod cap again.
(8) Measure the plastic gage at its widest point.
Standard oil clearance
0.018 - 0.036mm(0.0007 - 0.0014in.)
(9) If the plastic gage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
CAUTION:
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastic gage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
NOTE:
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
CAUTION:
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.
Connecting Rod Mark Location
Discrimination Of Connecting Rod
Crankshaft Pin Mark Location
Discrimination Of Crankshaft
Discrimination Of Crankshaft
Place Of Identification Mark (Connecting Rod Bearing)
Discrimination Of Connecting Rod Bearing
(11) Select the proper connecting rod bearing from the table below.
3. Check the connecting rod.
(1) When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction.
(2) If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it.
(3) Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with a press. If the rod is bent or twisted excessily, replace it.
Bending : 0.05mm/100mm(0.0020in./3.9370in.)
Torsion : 0.1mm/100mm(0.0039in./3.9370in.)
NOTE:
When assembling the rod without a bearing, there should be no difference.
4. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastic gage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
M8 : 15.7Nm(1.6 kgf.m, 11.6lb-ft) + 90°
M10 : 29.4 Nm(3.0 kgf.m, 21.7lb-ft)+ 90°
NOTE:
Tighten the bolts in order.
(5) Remove the cap and bearing again, and measure the widest part of the plastic gage.
Standard oil clearance
0.004 - 0.022mm (0.0002 - 0.0009in.)
(6) If the plastic gage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
CAUTION:
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7) If the plastic gage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
NOTE:
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
CAUTION:
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.
Crankshaft bore mark location
Letters have been stamped on the block as a mark for the each size of the 4 main journal bores.
No.1 journal stamping mark starts from the front of the engine.
Use the size marks which are stamped on the block and the crankshaft for the journal bore inner diameter and the journal outer diameter to choose the correct bearings.
Discrimination Of Cylinder Block
Crankshaft Journal Mark Location
Discrimination Of Crankshaft
Discrimination Of Crankshaft
Place Of Identification Mark (Crankshaft Bearing)
Discrimination Of Crankshaft Bearing
Selection Table
5. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play
0.07 - 0.25mm (0.0028 - 0.0098in.)
[Limit]
0.3mm(0.0118in.)
If the end play is greater than the maximum, replace the center bearing.
Thrust bearing thickness
1.925 - 1.965mm(0.0758 - 0.0774in.)
6. Inspect the main journals and the pin journals of the crankshaft.
7. Using a micrometer, measure the outer diameter of each main journal and pin journal.
Main journal diameter :
61.982 - 62.000mm (2.4402 - 2.4409in.)
Crank pin diameter :
47.982 - 48.000mm (1.8891 - 1.8898in.)
