Inspection After Disassembly
CRANKSHAFT SIDE CLEARANCE
^ Using a dial gauge, measure the clearance between the thrust bearings and the crankshaft arm when the crankshaft is moved fully forward or backward.
Standard: 0.10 - 0.26 mm (0.0039 - 0.0102 inch)
Limit: 0.30 mm (0.0118 inch)
^ If the measured value exceeds the limit, replace the thrust bearings, and measure again. If it still exceeds the limit, replace the crankshaft.
CONNECTING ROD SIDE CLEARANCE
^ Measure side clearance between connecting rod and crankshaft arm with feeler gauge.
Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit: 0.50 mm (0.0197 inch)
^ If the measured value exceeds the limit, replace the connecting rod bearings, and measure again. If it still exceeds the limit, replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
^ Measure the inner diameter of piston pin bore with an inside micrometer.
Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 inch)
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin with a micrometer.
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 inch)
Piston and Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) - (Outer diameter of piston pinch)
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 inch)
^ If clearance exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each parts.
^ Refer to piston selection table to replace piston/piston pin assembly.
^ Refer to connecting rod bearing selection table to replace connecting rod.
NOTE:
^ The connecting rod small end grade and piston pin hole (piston pinch) grade are provided only for the parts installed at the plant. For service parts, no grades can be selected. Only 0 grade is available.
^ Refer to "CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)" for the values for each grade at the plant.
^ Regarding marks on piston head, Refer to "HOW TO SELECT A PISTON".
PISTON RING SIDE CLEARANCE
^ Measure side clearance of piston ring and piston ring groove with feeler gauge.
Standard
Top ring: 0.045 - 0.080 mm (0.0018 - 0.0031 inch)
2nd ring: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Oil ring: 0.065 - 0.135 mm (0.0026 - 0.0053 inch)
Limit
Top ring: 0.11 mm (0.0043 inch)
2nd ring: 0.10 mm (0.0039 inch)
If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
^ Check if inner diameter of cylinder bore is within specification. Refer to "PISTON TO CYLINDER BORE CLEARANCE"
^ Insert piston ring until middle of cylinder with piston, and measure gap.
Standard
Top ring: 0.21 - 0.31 mm (0.0083 - 0.0122 inch)
2nd ring: 0.32 - 0.47 mm (0.0126 - 0.0185 inch)
Oil ring: 0.20 - 0.60 mm (0.0079 - 0.0236 inch)
Limit
Top ring: 0.54 mm (0.0213 inch)
2nd ring: 0.67 mm (0.0264 inch)
Oil ring: 0.95 mm (0.0374 inch)
^ If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.
CONNECTING ROD BEND AND TORSION
^ Check with connecting rod aligner.
Bend limit: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) length
Torsion limit: 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length
^ If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING (BIG END)
^ Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod bolt to the specified torque, measure the connecting rod big end inner diameter using an inside micrometer.
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 inch)
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
^ Measure inner diameter of bushing.
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 inch)
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin.
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 inch)
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) - (Outer diameter of piston pinch)
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
^ If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
^ If replacing the piston and piston pin assembly, refer to the "Piston Selection Table" to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to "HOW TO SELECT A PISTON".
Factory Installed Parts Grading:
1 of 2
2 of 2
^ Service parts apply only to grade 0.
CYLINDER BLOCK DISTORTION
^ Using a scraper, remove gasket on the cylinder block surface, and also remove oil, scale, carbon, or other contamination.
CAUTION: Be careful not to allow gasket debris to enter the oil or coolant passages.
^ Measure the distortion on the block upper face at some different points in 6 directions.
Limit: 0.1 mm (0.004 inch)
^ If out of the distortion limit, replace the cylinder block.
INNER DIAMETER OF MAIN BEARING HOUSING
^ Install the main bearing caps with the main bearings removed and tighten the mounting bolts to the specified torque.
^ Using a bore gauge, measure the inner diameter of the main bearing housing.
Standard: 58.944 - 58.967 mm (2.3206 - 2.3215 inch)
^ If out of the standard, replace the cylinder block and lower cylinder block assembly.
NOTE: These components cannot be replaced as a single unit because they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
^ Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at 6 different points on each cylinder. (X and Y directions at A, B and C). The Y axis is in the longitudinal direction of the engine.
NOTE: When determining cylinder bore grade, measure cylinder bore at B position.
Standard inner diameter: 89.000 - 89.030 mm (3.5039 - 3.5051 inch)
Wear limit: 0.2 mm (0.008 inch)
Out-of-round (difference between X - Y): 0.015 mm (0.0006 inch)
Taper limit (difference between C - A): 0.01 mm (0.0004 inch)
^ If the measured value rebore exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone the inner wall.
^ An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance of the piston cylinder satisfies the standard.
Over size (OS): 0.2 mm (0.008 inch)
Outer Diameter of Piston
^ Measure piston skirt diameter.
Standard: 88.980 - 89.010 mm (3.5031 - 3.5043 inch)
^ Measure point (distance from the top): 42 mm (1.65 inch)
Piston to Cylinder Bore Clearance
^ Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) - (Outer diameter of piston skirt).
Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
Limit: 0.08 mm (0.0031 inch)
^ If it exceeds the limit, replace piston/piston pin assembly.
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A".
Rebored size calculation: D = A + B - C
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 inch)
2. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores.
^ 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 specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
^ Measurement should be done after cylinder bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
^ Measure outer diameter of crankshaft journals.
Standard: 54.955 - 54.979 mm (2.1636 - 2.1645 inch)
OUTER DIAMETER OF CRANKSHAFT PIN
^ Measure outer diameter of crankshaft pin.
Standard: 44.956 - 44.974 mm (1.7699 - 1.7706 inch)
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
^ Using a micrometer, measure the dimensions at four different points shown in the figure on each journal and pin.
^ 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 (X - Y): 0.005 mm (0.0002 inch)
Taper (A - B): 0.005 mm (0.0002 inch)
CRANKSHAFT RUNOUT
^ Place a V-block on a precise flat table to support the journals on both ends of the crankshaft.
^ Place a dial gauge straight up on the No. 3 journal.
^ While rotating the crankshaft, read the movement of the pointer on the dial gauge, the total indicator reading.
Limit: 0.05 mm (0.002 inch)
OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
^ Install the connecting rod bearings to the connecting rod and the cap, and tighten the connecting rod bolts to the specified torque. Using a inside micrometer measure the inner diameter of connecting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) - (Outer diameter of crankshaft pinch)
Standard: 0.028 - 0.045 mm (0.0011 - 0.0018 inch)
Limit: 0.10 mm (0.0039 inch)
^ If clearance cannot be adjusted within the standard, grind crankshaft pin and use undersized bearing. Refer to "HOW TO SELECT A CONNECTING ROD BEARING".
Method of Using Plastigage
^ Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
^ Cut the Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod bolts to the specified torque.
CAUTION: Never rotate the crankshaft.
^ Remove the connecting rod cap and bearings, and using the scale on the Plastigage ban, measure the Plastigage width.
NOTE: The procedure when the measured value exceeds the limit is same as that described in the method by calculation.
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
^ Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter with the bearing cap bolt tightened to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal)
Standard:
No. 1, 3, and 5 journals: 0.012 - 0.022 mm (0.0005 - 0.0009 inch)
No. 2 and 4 journals: 0.018 - 0.028 mm (0.0007 - 0.0011 inch)
Limit: 0.1 mm (0.004 inch)
^ If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to "HOW TO SELECT A MAIN BEARING".
Method of Using Plastigage
^ Remove oil and dust on the crankshaft journal and the surfaces of each bearing completely.
^ Cut the Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
^ Tighten the main bearing bolts to the specified torque.
CAUTION: Never rotate the crankshaft.
^ Remove the bearing cap and bearings, and using the scale on the plastigage ban, measure the plastigage width.
NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".
CRUSH HEIGHT OF MAIN BEARING
^ When the 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.
OUTER DIAMETER OF LOWER CYLINDER BLOCK MOUNTING BOLT
^ Perform only with M10 (0.39 inch) bolts.
^ Measure outer diameters (d1, d2) at two positions as shown.
^ Measure d2 at a point within block A
^ When the value of d1- d2 exceeds the limit (a large difference in dimensions), replace the bolt with a new one.
Limit: 0.13 mm (0.0051 inch) or more
OUTER DIAMETER OF CONNECTING ROD BOLT
^ Measure outer diameter (d) at position shown in the figure
^ When "d" exceeds the limit (when it becomes thinner), replace the bolt with a new one.
Limit: 7.75 mm (0.3051 inch) or less
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODEL)
NOTE:
^ Inspection for double mass flywheel only.
^ Do not disassemble double mass flywheel.
Flywheel Deflection
^ Measure deflection of flywheel contact surface to the clutch with a dial clause.
^ Measure deflection at 210 mm (8.27 inch) dia.
Standard: 0.45 mm (0.0177 inch) or less
Limit: 1.3 mm (0.051 inch) or less
^ When measured value exceeds the limit, replace the flywheel with a new one.
Movement Amount in Radial (Rotation) Direction
Check the movement amount in the following procedure.
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel center line.
^ Tighten bolt to keen it from loosening at a force of 9.8 Nm (1 kg-m. 87 inch lbs.).
2. Put a mating mark on circumferences of the two flywheel masses without applying any load (measurement standard points).
3. Apply a force of 9.8 Nm (1 kg-m, 87 inch lbs.) in each direction, and mark the movement amount on the mass on the transmission side.
4. Measure dimensions of movement amounts A and B on circumference of the flywheel on the transmission side.
Standard: 28.3 mm (1.114 inch) or less
^ When measured value is outside the standard, replace flywheel.