Engine Block 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 inch)
Maximum end play: 0.35 mm (0.0138 inch)
^ If out-of-tolerance, install a new connecting rod.
^ If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2) Remove 2 connecting rod cap bolts.
3) Remove the connecting rod cap and bearing half.
4) Clean the crank pin and bearing.
5) Place Plastigage across the crank pin.
6) 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.
7) Remove 2 bolts, connecting rod cap and bearing halt
8) Measure the Plastigage at its widest point.
Standard oil clearance 0.028 - 0.046 mm (0.0011 - 0.0018 inch)
9) 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.
10) 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:
DISCRIMINATION OF CRANKSHAFT:
PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING) DISCRIMINATION OF CONNECTING ROD BEARING:
DISCRIMINATION OF CONNECTING ROD BEARING:
11) Selection:
3. Check the crankshaft bearing oil clearance.
1) To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2) Clean each main journal and bearing half with a clean shop tower.
3) Place one strip of Plastigage across each main journal.
4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque 26.46 Nm (2.7 kgf.m, 19.52 ft. lbs.) + 45°
NOTE: Do not turn the crankshaft.
5) Remove the cap and bearing again, and measure the widest part of the Plastigage.
Standard oil clearance 0.026 - 0.048 mm (0.0010 - 0.0019 inch)
6) 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.
7) 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 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 inch) or less
Allowable twist of connecting rod: 0.1 mm/100 mm (0.0039 in./3.94 inch) or less
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:
DISCRIMINATION OF CRANKSHAFT:
PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING) DISCRIMINATION OF 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 0.07 - 0.25 mm (0.0027 - 0.0098 inch)
Limit: 0.30 mm (0.01 18 inch)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness 1.925 - 1.965 mm (0.0758 - 0.07736 inch)
5. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter: 51.942 - 51.960 mm (2.0449 - 2.0456 inch)
Crank pin diameter: 47.954 - 47.972 mm (1.8879 - 1.8886 inch)
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 inch)
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 88.00 - 88.03 mm (3.4645 - 3.4657 inch)
NOTE: Measure position (from the bottom of the cylinder block) 110.7 mm (4.3582 inch)/160 mm (6.2992 inch)/210 mm (8.2677 inch)
6. Check the cylinder bore size code on the cylinder block.
7. Check the piston size code on the piston top face.
NOTE: Stamp the grade mark of basic diameter with rubber stamp.
8. Select the piston related to cylinder bore class.
Clearance: 0.02 - 0.04 mm (0.00078 - 0.00157 inch)
PISTON AND RINGS
1. Clean piston
1) Using a gasket scraper, remove the carbon from the piston top.
2) Using a groove cleaning tool or 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 47 mm (1.85 inch) from the top land of the piston.
Standard diameter 87.97 - 88.00 mm (3.4633 - 3.4645 inch)
3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
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 inch)
No. 2 0.03 - 0.07 mm (0.0012 - 0.0027 inch)
Oil ring: 0.06 - 0.15 mm (0.0024 - 0.0059 inch)
Limit
No. 1 0.1 mm (0.004 inch)
No. 2 0.1 mm (0.004 inch)
Oil ring: 0.2 mm (0.008 inch)
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 0.15 - 0.30 mm (0.0059 - 0.0118 inch)
No. 2 0.30 - 0.45 mm (0.0118 - 0.0177 inch)
Oil ring: 0.20 - 0.70 mm (0.0079 - 0.0275 inch)
Limit
No. 1 0.6 mm (0.0236 inch)
No. 2 0.7 mm (0.0275 inch)
Oil ring: 0.8 mm (0.0315 inch)
PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter 21.001 - 21.006 mm (0.8268 - 0.8270 inch)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance 0.01 - 0.02 mm (0.0004 - 0.0008 inch)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference 0.016 - 0.032 mm (0.00063 - 0.00126 inch)
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed.
If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.