Operation CHARM: Car repair manuals for everyone.

Inspection After Disassembly

Inspection After Disassembly

CRANKSHAFT END PLAY





^ Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator.
Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit: 0.30 mm (0.0118 inch)
^ If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

CONNECTING ROD SIDE CLEARANCE





^ Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge.
Standard: 0.20 - 0.35 mm (0.008 - 0.014 inch)
Limit: 0.40 mm (0.016 inch)
^ If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter





Measure the inner diameter of piston pin hole with an inside micrometer.
Standard: 21.993 - 22.005 mm (0.8659 - 0.8663 inch)

Piston Pin Outer Diameter





Measure the outer diameter of piston pin with a micrometer.
Standard: 21.989 - 22.001 mm (0.8657 - 0.8662 inch)

Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 inch)
^ If the calculated value is out of the standard, replace piston and piston pin assembly. When replacing piston and piston pin assembly, refer to EM-136, HOW TO SELECT PISTON. How to Select Piston and Bearing

NOTE:
^ Piston is available together with piston pin as assembly
^ Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only 0 grade is available.)

PISTON RING SIDE CLEARANCE





^ Measure the side clearance of piston ring and piston ring groove with a feeler gauge.
Standard:
Top ring: 0.045 - 0.080 mm (0.002 - 0.003 inch)
2nd ring: 0.030 - 0.070 mm (0.001 - 0.003 inch)
Oil ring: 0.065 - 0.135 mm (0.003 - 0.005 inch)
Limit:
Top ring: 0.11 mm (0.004 inch)
2nd ring: 0.10 mm (0.004 inch)
^ If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

PISTON RING END GAP





^ Make sure that the cylinder bore inner diameter is within the specification.
^ Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with a feeler gauge.
Standard:
Top ring: 0.23 - 0.33 mm (0.009 - 0.013 inch)
2nd ring: 0.33 - 0.48 mm (0.013 - 0.019 inch)
Oil ring: 0.20 - 0.50 mm (0.008 - 0.020 inch)
Limit:
Top ring: 0.54 mm (0.021 inch)
2nd ring: 0.80 mm (0.031 inch)
Oil ring: 0.95 mm (0.037 inch)
^ If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.

CONNECTING ROD BEND AND TORSION





^ Check with a connecting rod aligner.
Bend:
Limit: 0.15 mm (0.006 inch) per 100 mm (3.94 inch) length
Torsion:
Limit: 0.30 mm (0.012 inch) per 100 mm (3.94 inch) length
^ If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER





^ Install connecting rod bearing cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque.
^ Measure the inner diameter of connecting rod big end with an inside micrometer.
Standard: 55.000 - 55.013 mm (2.1654 - 2.1659 inch)
^ If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter





Measure the inner diameter of connecting rod bushing with an inside micrometer.
Standard: 22.000 - 22.012 mm (0.8661 - 0.8666 inch)

Piston Pin Outer Diameter





Measure the outer diameter of piston pin with a micrometer.
Standard: 21.989 - 22.001 mm (0.8657 - 0.8662 inch)

Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inter)
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
Limit: 0.030 mm (0.0012 inch)
^ If the calculated value exceeds the limit, replace connecting rod assembly
^ If replacing piston and piston pin assembly, refer to EM-136, HOW TO SELECT PISTON. How to Select Piston and Bearing





^ If replacing connecting rod assembly, refer to EM-147, CONNECTING ROD BEARING OIL CLEARANCE to select the connecting rod bearing.

Factory installed parts grading:
^ Service parts apply only to grade 0.








CYLINDER BLOCK DISTORTION
^ Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination.

CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.





^ Measure the distortion on the cylinder block upper face at some different points in six directions with a straightedge and a feeler gauge.
Limit: 0.1 mm (0.004 inch)
^ If it exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INNER DIAMETER





^ Install main bearing caps and main bearing beam without installing main bearings, and tighten main bearing cap bolts to the specified torque.
^ Measure the inner diameter of main bearing housing with a bore gauge.
Standard: 63.993 - 64.017 mm (2.5194 - 2.5203 inch)
^ If out of the standard, replace cylinder block and main bearing caps as assembly.

NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with main bearing caps.

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore inner Diameter





^ Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. (X and Y directions at A, B and C) (Y is in longitudinal direction of engine)
Standard inner diameter: 95.500 - 95.530 mm (3.7598 - 3.7610 inch)
Wear limit: 0.20 mm (0.0079 inch)
Out-of-round (Difference between X and Y):
Limit: 0.015 mm (0.0006 inch)
Taper (Difference between A and C):
Limit: 0.010 mm (0.0004 inch)





^ If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the inner wall.
^ Oversize piston is provided. When using oversize piston, rebore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard.

CAUTION: When using oversize piston, use oversize pistons for all cylinders with oversize piston rings.

Oversize (OS): 0.2 mm (0.008 inch)

Piston Skirt Diameter





Measure the outer diameter of piston skirt with a micrometer.
Measure point: Distance from the top 41.0 mm (1.614 inch)
Standard: 95.480 - 95.510 mm (3.7590 - 3.7602 inch)

Piston-to-Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction Y position B).
(Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).
Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
Limit: 0.08 mm (0.0031 inch)

^ If the calculated value exceeds the limit, replace piston and piston pin assembly.

Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bored size calculation: D = A + B - C where,
D: Bored diameter
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 inch)
2. Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores.

NOTE:
^ When any cylinder needs boring, all other cylinders must also be bored.
^ Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 inch) or so in diameter at a time.

4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.

NOTE: Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER





^ Measure the outer diameter of crankshaft main journals with micrometer.
Standard: 59.951 - 59.975 mm (2.3603 - 2.3612 inch) dia.
^ If out of the standard, measure the main bearing oil clearance. Then use undersize bearing.

CRANKSHAFT PIN JOURNAL DIAMETER





^ Measure the outer diameter of crankshaft pin journal with micrometer.
Standard: 51.956 - 51.974 mm (2.0455 - 2.0462 inch) dia.
^ If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing.

CRANKSHAFT OUT-OF-ROUND AND TAPER
^ Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer.
^ Out-of-round is indicated by the difference in the dimensions between X and Y at A and B.
^ Taper is indicated by the difference in the dimensions between A and B at X and Y.
Limit:
Out-of-round (Difference between X and Y: 0.002 mm (0.0001 inch)
Taper (Difference between A and B): 0.002 mm (0.0001 inch)
If the measured value exceeds the limit, correct or replace crankshaft. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select the main bearing and/or connecting rod bearing.

CRANKSHAFT RUNOUT





^ Place V-block on precise flat table, and support the journals on the both end of crankshaft.
^ Place a dial indicator straight up on the No. 3 journal.
^ While rotating crankshaft, read the movement of the pointer on a dial indicator. (Total indicator reading)
Standard: Less than 0.05 mm (0.0020 inch)
Limit: 0.10 mm (0.0039 inch)
^ If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation





^ Install connecting rod bearings to connecting rod and connecting rod cap, and tighten connecting rod bolts to the specified torque.
^ Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) - (crankshaft pin journal diameter)
Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 inch) (actual clearance)
Limit: 0.070 mm (0.0028 inch)
^ If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance.

Method of Using Plastigage
^ Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
^ Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque.

CAUTION: Do not rotate crankshaft.





^ Remove connecting rod bearing cap and bearings, and using the scale on the plastigage bag, measure the pasturage width.

NOTE: The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation.

MAIN BEARING OIL CLEARANCE
Method by Calculation





^ Install main bearings to cylinder block and main bearing caps, and tighten main bearing cap bolts with main bearing beam to the specified torque.
^ Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter)
Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 inch) (actual clearance)
Limit: 0.065 mm (0.0026 inch)
^ If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance.

Method of Using Plastigage
^ Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely
^ Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Install main bearing to cylinder block and main bearing cap, and tighten main bearing bolts with main bearing beam to the specified torque.

CAUTION: Never rotate crankshaft.





^ Remove main bearing caps and bearings, and using the scale on the plastigage bag, measure the plastigage width.

NOTE: The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation.

MAIN BEARING CRUSH HEIGHT





^ When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude.
Standard: There must be crush height.
^ If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT





^ When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude.
Standard: There must be crush height.
^ If the standard is not met, replace connecting rod bearings.

MAIN BEARING CAP BOLT OUTER DIAMETER





^ Measure the outer diameters (d1, d2) at two positions as shown in the figure.
^ If reduction appears in A range, regard it as d2
Limit (d1 - d2): 0.11 mm (0.0043 inch)
^ If it exceeds the limit (large difference in dimensions), replace main bearing cap bolt with new one.

CONNECTING ROD BOLT OUTER DIAMETER





^ Measure the outer diameter d at position shown in the figure.
^ If the reduction appears in a position other than d, regard it as d.
Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit: 7.75 mm (0.3051 inch)
^ When d exceeds the limit (when it becomes thinner), replace connecting rod bolt with new one.

DRIVE PLATE





^ Check drive plate and signal plate for deformation or damage.

CAUTION:
^ Do not disassemble drive plate.
^ Do not place drive plate with signal plate facing down.
^ When handling signal plate, take care not to damage or scratch it.
^ Handle signal plate in a manner that prevents it from becoming magnetized.

^ If anything is found, replace drive plate.

OIL JET





^ Check nozzle for deformation and damage.
^ Blow compressed air from nozzle, and check for clogs.
^ If it is not satisfied, clean or replace oil jet.

OIL JET RELIEF VALVE
^ Using a clean plastic stick, press check valve in oil jet relief valve. Make sure that valve moves smoothly with proper reaction force.
^ If it is not satisfied, replace oil jet relief valve.