Inspection
INSPECTIONCONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play. Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play: 0.1 - 0.25 mm (0.004 - 0.010 in.)
^ If out-of-tolerance, install a new connecting rod.
^ If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
A. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
B. Remove 2 connecting rod cap bolts.
C. Remove the connecting rod cap and bearing half.
D. Clean the crank pin and bearing.
E. Place plastigage across the crank pin.
F. Reinstall the bearing half and cap, and torque the bolts.
Tightening torque 19.6 Nm (2.0 kgf.m, 14.46 ft. lbs.) + 90°
NOTE: Do not turn the crankshaft.
G. Remove 2 bolts, connecting rod cap and bearing half.
H. Measure the plastigage at its widest point.
Standard oil clearance 0.030 - 0.048 mm (0.0012 - 0.0019 in.)
I. If the plastigage 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.
J. If the plastigage 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:
PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING):
DISCRIMINATION OF CONNECTING ROD BEARING:
K. Selection
3. Check the crankshaft bearing oil clearance.
A. To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
B. Clean each main journal and bearing half with a clean shop tower.
C. Place one strip of plastigage across each main journal.
D. Reinstall the bearings and caps, then torque the bolts.
Tightening torque 49.00 Nm (5.0 kgf-m, 36.16 ft. lbs.) + 90° 19.60 Nm (2.0 kgf-m, 14.46 ft. lbs.) + 120° 29.40 - 31.36 Nm (3.0 - 3.2 kgf-m, 21.70 - 23.14 ft. lbs.)
NOTE: Do not turn the crankshaft.
E. Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance 0.022 - 0.040 mm (0.0009 - 0.0016 in.)
F. If the plastigage 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.
G. If the plastigage 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 size of each of the 5 main journal bores. Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
DISCRIMINATION OF CYLINDER BLOCK:
CRANKSHAFT JOURNAL MARK LOCATION
DISCRIMINATION OF CRANKSHAFT:
PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING):
DISCRIMINATION OF CRANKSHAFT BEARING:
SELECTION:
4. 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 0.10 - 0.28 mm (0.0039 - 0.0110 in.)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness 2.41 - 2.45 mm (0.0949 - 0.0964 in.)
5. Inspect main journals and crank pins Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter: 68.942 - 68.960 mm (2.7142 - 2.7149 in.) Crank pin diameter: 54.954 - 54.972 mm (2.1635 - 2.1642 in.)
CONNECTING RODS
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod: 0.05 mm / 100 mm (0.0020 in./3.94 in.) or less Allowable twist of connecting rod: 0.1 mm / 100 mm (0.0039 in./3.94 in.) or less
CYLINDER BLOCK
1. Remove gasket material. 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 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: Less than 0.05 mm (0.0020 in.), Less than 0.02 mm (0.0008 in.) / 150 x 150
4. Inspect cylinder bore diameter Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter 96.00 - 96.03 mm (3.7795 - 3.7807 in.)
6. Check the cylinder bore size code on the cylinder block.
7. Check the piston size code on the piston top face.
8. Select the piston related to cylinder bore class.
Clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 in.)
PISTON AND RINGS
1. Clean piston
A. Using a gasket scraper, remove the carbon from the piston top.
B. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
C. 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 14 mm (0.5512 in.) from the bottom of the piston.
Standard diameter 95.96 - 95.99 mm (3.7779 - 3.7791 in.)
3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance 0.03 - 0.05 mm (0.0012 - 0.0020 in.)
4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard No.1: 0.03 - 0.07 mm (0.0012 - 0.0027 in.) No.2: 0.03 - 0.07 mm (0.0012 - 0.0027 in.) Oil ring: 0.06 - 0.15 mm (0.0024 - 0.0059 in.) Limit No.1: 0.1 mm (0.004 in.) No.2: 0.1 mm (0.004 in.) Oil ring: 0.2 mm (0.008 in.)
If the clearance is greater than 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 against the wear limits. If the bore is over the service limit, the cylinder block must be replaced.
Piston ring end gap
Standard No.1: 0.17 - 0.32 mm (0.0067 - 0.0126 in.) No.2: 0.32 - 0.47 mm (0.0126 - 0.0185 in.) Oil ring: 0.20 - 0.70 mm (0.0079 - 0.0275 in.) Limit No.1: 0.6 mm (0.0236 in.) No.2: 0.7 mm (0.0275 in.) Oil ring: 0.8 mm (0.0315 in.)
PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter 23.002 - 23.006 mm (0.9056 - 0.9057 in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance 0.009 - 0.017 mm (0.0004 - 0.0007 in.)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference -0.032 - -0.017 mm (-0.0012 - -0.0007 in.)