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.)
Cylinder Block
1. Remove gasket materials.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : 0.03mm(0.0012in.) or less
4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block or process the piston to be oversized.
5. Inspect the cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter
86.70 - 86.73mm (3.4134 - 3.4146in.)
6. Check the cylinder bore size code(A) on the cylinder block.
7. Check the piston size code(A) on the piston top face.
8. Select the proper piston related to the cylinder bore class.
Clearance : 0.02 - 0.04mm(0.0008 - 0.0016in.)
Cylinder Boring
1. The over size piston is chosen on the maximum inner diameter of the cylinder.
NOTE:
The piston size mark is on the top surface of the piston.
2. Measure the outer diameter of the piston which is installed before.
3. Calculate the new bore size with the measurement in the step 2.
New bore size = measured outer diameter of piston + 0.02 - 0.04mm (0.0008 - 0.0016in.)[clearance] - 0.01mm(0.0004in.)[for horning]
4. Bore the cylinder to the calculated size.
CAUTION:
Bore the cylinders in firing order to prevent the cylinders from be twisted by high temperature.
5. Stop boring and start horning for the proper clearance.
6. Measure the clearance between a piston and a cylinder.
Specification
0.02 - 0.04mm(0.0008 - 0.0016in.)
NOTE:
Bore all the cylinders with the same over size.
Piston And Rings
1. Clean pistons.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
NOTE:
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 13.5 mm (0.5315 in) from the bottom of the piston.
Standard diameter
86.67 - 86.70(3.4122 - 3.4134in.)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance
0.02 - 0.04mm(0.0008 - 0.0016in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between a new piston ring and the ring groove.
Piston ring side clearance
Standard
No.1 : 0.04 - 0.08mm (0.0016 - 0.0031in.)
No.2 : 0.03 - 0.07mm (0.0012 - 0.0027in.)
Oil ring : 0.06 - 0.15mm (0.0024 - 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
If the clearance is greater than the maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is over the service limit, the cylinder block must be replaced or bored
Piston ring end gap
Standard
No.1 : 0.15 - 0.30mm (0.0059 - 0.0118in.)
No.2 : 0.30 - 0.45m (0.0118 - 0.0177in.)
Oil ring : 0.20 - 0.70mm (0.0079 - 0.0275in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)
Piston Pins
1. Measure the outer diameter of the piston pin.
Piston pin outer diameter
21.001 - 21.007mm (0.8268 - 0.8270in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.011 - 0.018mm (0.0004 - 0.0007in.)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference
-0.033 ~ -0.016mm (-0.0013 ~ -0.0006in.)