Inspection

CYLINDER BLOCK

Inspection


CRANKSHAFT END PLAY






- Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A).
Standard and Limit: Refer to "Cylinder Block" [1][2]Specifications.
- 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 (A).
Standard and Limit: Refer to "Cylinder Block" [1][2]Specifications.
- 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 (A).
Standard : Refer to "Cylinder Block" [1][2]Specifications.
Piston Pin Outer Diameter





Measure the outer diameter of piston pin with a micrometer (A).
Standard : Refer to "Cylinder Block" [1][2]Specifications.
Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)
Standard : Refer to "Cylinder Block" [1][2]Specifications.
- If oil clearance is out of the standard, replace piston and piston pin assembly.
- When replacing piston and piston pin assembly, refer to "Piston" Service and Repair.
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 grades can be selected. (Only grade "0" is available.)

PISTON RING SIDE CLEARANCE






- Measure the side clearance of piston ring and piston ring groove with a feeler gauge.
Standard and Limit: Refer to "Cylinder Block" [1][2]Specifications.
- 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

- Check that cylinder bore inner diameter is within specification. Refer to "Cylinder Bore Inner Diameter".





- Lubricate with new engine oil to piston (1) and piston ring (2), and then insert (A) piston ring until middle of cylinder (B) with piston, and measure piston ring end gap with a feeler gauge (C).
Standard and Limit: Refer to "Cylinder Block" [1][2]Specifications.
- If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, rebore cylinder and use oversized piston and piston rings.

CONNECTING ROD BEND AND TORSION






- Check with a connecting rod aligner.





Bend and Torsion: Refer to "Cylinder Block" [1][2]Specifications.
- If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER






- Install connecting rod cap (1) without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.





- Measure the inner diameter of connecting rod big end with an inside micrometer.
Standard: Refer to "Cylinder Block" [1][2]Specifications.
- 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 (A).
Standard: Refer to "Cylinder Block" [1][2]Specifications.
Piston Pin Outer Diameter





Measure the outer diameter of piston pin with a micrometer (A).
Standard: Refer to "Cylinder Block" [1][2]Specifications.
Connecting Rod Bushing Oil Clearance (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) - (Piston pin outer diameter)
Standard: Refer to "Cylinder Block" [1][2]Specifications.
- If the measured value is out of the standard. Replace connecting rod assembly and/or piston and piston pin assembly.
- If replacing piston and piston pin assembly. Refer to "Piston" Service and Repair.
- If replacing connecting rod assembly. Refer to "Connecting Rod Bearing" Connecting Rod Bearing to select connecting rod bearing.

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 straight edge (A) and feeler gauge (B).
Limit: Refer to "Cylinder Block" [1][2]Specifications.
- If it exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INNER DIAMETER

- Install lower cylinder block without main bearings installed, and tighten lower cylinder block mounting bolts to the specified torque. Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.





- Measure the inner diameter of main bearing housing with a bore gauge.
Standard: Refer to "Cylinder Block" [1][2]Specifications.
- If out of the standard, replace cylinder block (1) and lower cylinder block (2) assembly.
NOTE:
Cylinder block cannot be replaced as a single, because it is machined together with lower cylinder block.

PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter





- Using a bore gauge, measure the 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)
NOTE:
When determining cylinder bore grade, measure the cylinder bore at "B" position.

Standard:
Cylinder bore inner diameter
: Refer to "Cylinder Block" [1][2]Specifications.

Limit:
Out-of-round (Difference between "X" and "Y")
Taper (Difference between "A" and "B")
: Refer to "Cylinder Block" [1][2]Specifications.

- 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 cylinder inner wall.
- Oversize piston is provided. When using oversize piston, rebore the cylinder so that the clearance of the piston to cylinder bore satisfies the standard.

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

Oversize (O/S): 0.2 mm (0.008 in)

Piston Skirt Diameter





Measure the outer diameter of piston skirt with a micrometer (A).
Standard: Refer to "Cylinder Block" [1][2]Specifications.
Piston to Cylinder Bore Clearance





Calculate by piston skirt diameter and cylinder bore inner diameter (direction "X", position "B").
(Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter)
Standard and Limit: Refer to "Cylinder Block" [1][2]Specifications.
- If it exceeds the limit, replace piston and piston pin assembly.
Refer to "Piston" Service and Repair.
Reboring Cylinder Bore
1.Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

Rebored size calculation: D = A + B - C
where,
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
D: Bored diameter

2.Install lower cylinder block, and tighten mounting bolts to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.
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 in) or so in diameter at a time.
4.Hone cylinders to obtain specified piston to cylinder bore clearance.
5.Measure the finished cylinder bore for 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 a micrometer (A).
Standard: Refer to "Cylinder Block" [1][2]Specifications.
- If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to "Main Bearing" Service and Repair.

CRANKSHAFT PIN JOURNAL DIAMETER

- Measure the outer diameter of crankshaft pin journal with a micrometer.
Standard: Refer to "Cylinder Block" [1][2]Specifications.
- If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to "Connecting Rod Bearing" Connecting Rod Bearing.

OUT-OF-ROUND AND TAPER OF CRANKSHAFT






- 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 dimensions between
"X" and "Y" at "A" and "B".
- Taper is indicated by the difference in dimension between "A" and
"B" at "X" and "Y".

Limit:
Out-of-round (Difference between "X" and "Y")
Taper (Difference between "A" and "B")
: Refer to "Cylinder Block" [1][2]Specifications.

- 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 main bearing and/or connecting rod bearing. Refer to "Connecting Rod Bearing" [1][2]Connecting Rod Bearing and/or "Main Bearing" Specifications.

CRANKSHAFT RUNOUT

- Place a V-block on a precise flat table to support the journals on the both end of the crankshaft.





- Place a dial indicator straight up on the No. 3 journal.
- While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading)
Limit: Refer to "Cylinder Block" [1][2]Specifications.
- If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation





- Install connecting rod bearings (2) to connecting rod (3) and cap, and tighten connecting rod bolts to the specified torque. Refer to
"Disassembly and Assembly" Disassembly And Assembly for tightening procedure.





- Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter)
Standard and Limit: Refer to "Connecting Rod Bearing" [1][2]Connecting Rod Bearing.
- If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to "Connecting Rod Bearing" Connecting Rod Bearing.
Method of Using Plastigage
- Remove engine oil and dust on crankshaft pin 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 cap, and tighten connecting rod bolts to the specified torque. Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.

CAUTION:
Never rotate crankshaft.





- Remove connecting rod cap and bearing, 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 OIL CLEARANCE

Method by Calculation





- Install main bearings (3) to cylinder block (1) and lower cylinder block (2), and tighten lower cylinder block mounting bolts to the specified torque. Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.





- Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter)
Standard and Limit: Refer to "Main Bearing" Specifications.
- If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to "Disassembly and Assembly" Disassembly And Assembly.
Method of Using Plastigage
- Remove engine oil and dust on crankshaft main 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 bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting bolts to the specified torque. Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.

CAUTION:
Never rotate crankshaft.





- Remove lower cylinder block 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 lower cylinder block is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude (B). Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.





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 (1) installed, the tip end of bearing must protrude (B). Refer to "Disassembly and Assembly" Disassembly And Assembly for the tightening procedure.





Standard: There must be crush height.
- If the standard is not met, replace connecting rod bearings.

LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER

- Perform only with M10 bolts.





- 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"): 0.13 mm (0.0051 in)
- If it exceeds the limit (a large difference in dimensions), replace lower cylinder block mounting bolt with a new one.

CONNECTING ROD BOLT OUTER DIAMETER






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