Cylinder Block Inspection/Repair
CYLINDER BLOCK INSPECTION / REPAIR
1. Measure the distortion of the cylinder block top surface in the six directions as shown. Repair by grinding or replace as necessary.
Cylinder block distortion 0.05 mm (0.002 inch) maximum
Cylinder block height 270.9-271.1 mm (10.666-10.673 inch)
Grinding 0.20 mm (0.008 inch) maximum
2. Measure the cylinder bores in X and Y directions at 67 mm (2.64 inch) below the top surface.
3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained.
^ Note: Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter.
Cylinder Bore
Wear limit 0.15 mm (0.006 inch)
Oil Jet Inspection
1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. If not, replace the oil jet valve.
Air pressure 167 - 225 kPa (1.7 - 2.3 kgf/cm2, 25 - 32 psi)
2. Inspect the oil jet nozzle for clogs. Replace the nozzle as necessary.
Oil Jet Removal/Installation
Removal
1. Drill a hole into the center of the oil jet head with a 7 mm {O.28 in} drill bit.
2. Remove the spring and ball through the hole.
3. Tap the hole with a M8 x 1.25 tap to 8 mm {O.31 in} deep.
4. Screw a M8 x 1.25 bolt into the tapped hole.
5. Attach the sliding hammer to the bolt.
Caution
Twisting or turning the sliding hammer while removing the 011 Jet can damage the cylinder block.
6. Pull the sliding hammer straight upward and discard the oil jet
Installation
1. Temporarily install the crankshaft, connecting rod, and piston to the cylinder block.
2. Coat the oil jet into the hole and align the nozzle with the piston's notch.
3. Fit the oil jet into the hole and align the nozzle with the piston's notch.
4. Put the cylinder block on the press stand.
5. Verify that the oil jet nozzle is properly aligned.
Caution
If the 0il Jet nozzle Is not properly aligned after being pressed In, it can damage the oil jet, cylinder block and the piston.
6. Press-fit the oil jet into the cylinder block.
Depth
11.0-10.5 mm {O.44-0.41 in}
Pressure
3.2 kN {330 kgf , 726 Ibf} min.
Caution
Depth over specification can damage the oil jet nozzle.
Pressure below specification indicates loose fit. Replace the cylinder block and oil jet.
Piston Inspection
^ Measure the outer diameter of each piston at right angle (90°) to the piston pin, 16.5 mm (0.650 inch) below the oil ring groove lower edge.
Piston diameter
Piston Clearance Inspection / Repair
1. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit oversize piston as necessary.
Standard clearance 0.025 - 0.066 mm (0.0010 - 0.0025 inch)
Maximum clearance 0.15 mm (0.006 inch)
2. It the piston is replaced, the piston rings must also be replaced.
Piston Ring Clearance Inspection
1. Measure the piston ring-to-ring land clearance around the entire circumference. Replace the piston and piston ring as necessary.
Standard clearance
Top : 0.035 - 0.065 mm (0.0014 - 0.0025 inch)
Second: 0.030 - 0.065 mm (0.0012 - 0.0025 inch)
Oil: 0.022 - 0.065 mm (0.0009 - 0.0025 inch)
Maximum clearance
0.20 mm (0.008 inch)
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring as necessary.
Standard end gap
Top: 0.15 - 0.25 mm (0.006 - 0.009 inch)
Second: 0.15 - 0.30 mm (0.006 - 0.011 inch)
Oil rail: 0.20 - 0.70 mm (0.008 - 0.027 inch)
Maximum end gap 1.0 mm (0.039 inch)
Piston Pin Clearance Inspection
1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard diameter 18.988 - 19.000 mm (0.7476 - 0.7480 inch)
2. Measure each connecting rod small end inner diameter in X and Y directions as shown.
Standard diameter 18.943 - 18.961 mm (0.7458 - 0.7464 inch)
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard diameter 18.974 - 18.980 mm (0.7471 - 0.7472 inch)
4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin as necessary.
Standard clearance -0.008 - 0.026 mm (-0.0014 - 0.0010 inch)
5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.
Standard clearance 0.037 - 0.013 mm (0.0014 - 0.0005 inch)
Crankshaft Inspection
1. Measure the crankshaft runout. Replace the crankshaft as necessary.
Runout 0.03 mm (0.0012 inch) maximum
2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersized bearing as necessary.
Main Journal
Out-of-round 0.05 mm (0.002 inch) maximum
Crank Pin
Out-of-round 0.05 mm (0.002 inch) maximum
Crankshaft Oil Clearance Inspection / Repair
1. Position plastigage on the top of the journals in the axial direction.
2. Install the main bearing cap.
3. Remove the main bearing cap.
4. Measure the main journal oil clearance, If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersized bearings so that the specified oil clearance is obtained.
Standard clearance 0.024 - 0.050 mm (0.0010 - 0.0019 inch)
Maximum clearance 0.067 mm (0.0026 inch)
Crankshaft End Play Inspection / Repair
1. Install the main bearing cap.
2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the thrust bearing or grind the crankshaft and install an undersized bearing so that the specified end play is obtained.
Standard end play 0.080 - 0.282 mm (0.0032 - 0.0111 inch)
Maximum end play 0.30 mm (0.012 inch)
3. Remove the main bearing cap.
Connecting Rod Inspection
^ Measure each connecting rod for bending and distortion. Replace the connecting rod as necessary.
Bending 0.05 mm (0.0020 inch) maximum /50 mm (1.97 inch)
Distortion 0.05 mm (0.0020 inch) maximum /50 mm (1.97 inch)
Center-to-center distance 135.15 - 135.25 mm (5.3209 - 5.3247 inch)
Connecting Rod Oil Clearance Inspection/Repair
1. Position a plastigage on the top of the journals in the axial direction.
2. Install the connecting rod cap.
3. Remove the connecting rod cap.
4. Measure the crankpin oil clearance. If the clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersized bearings so that the specified clearance is obtained.
Standard clearance 0.024 - 0.061 mm (0.0010 - 0.0025 inch)
Maximum clearance 0.067 mm (0.0026 inch)
Connecting Rod Side Clearance Inspection
1. Install the connecting rod cap.
2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap as necessary.
Standard clearance 0.110 - 0.262 mm (0.005 - 0.010 inch)
Maximum clearance 0.30 mm (0.012 inch)
3. Remove the connecting rod cap.
Piston and Connecting Rod Inspection
^ Inspect the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
Tensioner Spring Inspection
^ Measure the free length of the tensioner spring. Replace the tensioner spring as necessary.
Free length 36.6 mm (1.44 inch)
Tensioner Inspection
^ Rotate the tensioner. If tensioner rotates with no resistance or does not rotate, replace the tensioner.
Bolt Inspection
Connecting rod bolt inspection
^ Measure the length of each connecting rod bolt. Replace as necessary.
Standard length46.7-17.3 mm {1.839-1.862 in}
Maximum length48.0 mm {1.890 in}
Main bearing cap bolt inspection
^ Measure the length of each main bearing cap bolt, Replace as necessary.
Standard length67.7--68.3 mm {2.666-2.688 in}
Maximum length69.0 mm {2.717 in}
Cylinder head bolt inspection
^ Measure the length of each cylinder head bolt. Replace as necessary.
Standard length104.2-104.8 mm {4.102--4.215 in}
Maximum length105.5 mm {4.154 in}
