Cylinder Block Inspection/Repair
CYLINDER BLOCK INSPECTION/REPAIR
1. Measure the distortion of the cylinder block top surface in the six directions as shown.
- If it is out of specification, repair by grinding or replace.
Cylinder block distortion 0.05 mm (0.0019 inch) max.
Cylinder block height 221.5 mm (8.720 inch)
Grinding 0.20 mm (0.008 inch) max.
2. Measure the cylinder bores in X and Y directions at 35 mm (1.38 inch) below the top surface.
- 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 (0.0059 inch)
Oil Jet Valve And Nozzle 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 clogging. Replace the nozzle if necessary.
Piston, Piston Ring And Piston Pin Inspection
1. Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 16.5 mm (0.6450 inch) below the oil ring groove lower edge.
Piston Diameter
2. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit oversize piston if necessary.
- If the piston is replaced, the piston rings must also be replaced.
Standard clearance 0.038 - 0.053 mm (0.0015 - 0.0020 inch)
Maximum clearance 0.10 mm (0.0039 inch)
3. Measure the piston ring-to-ring groove clearance around the entire circumference.
- If the groove clearance exceeds the maximum, replace the piston and piston ring.
Standard clearance
Top: 0.035 - 0.065 mm (0.0014 - 0.0025 inch)
Second: 0.030 - 0.070 mm (0.0012 - 0.0027 inch)
Oil: 0.060 - 0.150 mm (0.0024 - 0.0059 inch)
Maximum clearance
Top, Second: 0.15 mm (0.0059 inch)
Oil: 0.20 mm (0.008 inch)
4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
5. Measure each piston ring end gap using a feeler gauge. If the piston end gap is exceeds the maximum, replace the piston ring if necessary.
Standard end gap
Top: 0.15 - 0.30 mm (0.006 - 0.011 inch)
Second: 0.30 - 0.45 mm (0.012 - 0.017 inch)
Oil rail: 0.20 - 0.70 mm (0.008 - 0.027 inch)
Maximum end gap 1.0 mm (0.039 inch)
6. Measure each piston pin bore diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard diameter 19.988 - 20.000 mm (0.7870 - 0.7874 inch)
7. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard diameter 19.974 - 19.980 mm (0.7864 - 0.7866 inch)
8. Calculate the piston pin-to-piston pin bore clearance.
- If it is out of specification, replace the piston and/or piston pin if necessary.
Standard clearance 0.008 - 0.026 mm (0.0004 - 0.0010 inch)
9. Calculate the connecting rod small end-to-piston pin clearance.
- If it is out of specification, replace the connecting rod or piston pin.
Standard clearance 0.037 - 0.013 mm (0.0014 - 0.0005 inch)
Connecting Rod Inspection
1. Measure the connecting rod large end side clearance.
- If the clearance exceeds the maximum, replace the connecting rod and cap.
Standard clearance 0.110 - 0.262 mm (0.005 - 0.010 inch)
Maximum clearance 0.30 mm (0.012 inch)
2. Position a plastigage atop the journals in the axial direction.
3. Install the connecting rod cap. Refer to Engine; Service and Repair; Engine Disassembly/Assembly.
4. Remove the connecting rod cap.
5. 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 0.028 - 0.048 mm (0.0012 - 0.0018 inch)
Maximum clearance 0.10 mm (0.0039 inch)
6. Measure each connecting rod small end inner diameter in X and Y directions as shown.
Standard diameter 19.943 - 19.961 mm (0.7852 - 0.7858 inch)
7. Measure each connecting rod for bending and distortion.
- If it is out of specification, replace the connecting rod.
Bending 0.05 mm (0.0020 inch) max. /50 mm (1.97 inch)
Distortion 0.07 mm (0.0027 inch) max. /50 mm (1.97 inch)
Center-to-center distance 132.85 - 132.95 mm (5.2304 - 5.2342 inch)
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 and/or the piston pin.
Crankshaft Inspection/Repair
1. 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)
2. Measure the crankshaft runout.
- If it is out of specification, replace the crankshaft if necessary.
Runout 0.04 mm (0.0016 inch) max.
3. Measure the journal diameter in X and Y direction at the two points (A and B) as shown.
- If it is out of specification, replace the crankshaft or grind the journal and install the undersized bearing.
Main Journal
Out-of-round 0.05 mm (0.002 inch) max.
Crank Pin
Out-of-round 0.05 mm (0.002 inch) max.
4. Measure the main journal oil clearances as follows.
1. Position a plastigage atop the journals in the axial direction.
2. Install the main bearing cap. Refer to Engine; Service and Repair; Engine Disassembly/Assembly.
3. Remove the main bearing cap. Refer to Engine; Service and Repair; Engine Disassembly/Assembly.
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 0.018 - 0.036 mm (0.0008 - 0.0014 inch)
Maximum clearance 0.10 mm (0.0039 inch)