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
Diameter of Piston Pin Bore
Measure the diameter of piston pin bore with an inside micrometer.
Outer Diameter of Piston Pin
Measure outer diameter of piston pin with a micrometer.
Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) - (Outer diameter of piston pin)
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 pin) grade are provided only for the parts installed at the plant. For service parts, no grades can be selected. Only 0 grade is available.
^ Regarding marks on piston head,
PISTON RING SIDE CLEARANCE
Measure side clearance of piston ring and piston ring groove with feeler gauge.
^ 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.
^ Insert piston ring until middle of cylinder.
^ 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.
^ 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.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
^ Measure inner diameter of bushing.
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End) (Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) - (Outer diameter of piston pin)
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.
Factory Installed Parts Grading:
^ Service parts apply only to Grade 0.
CYLINDER BLOCK DISTORTION
^ Using a scraper, remove gasket on the cylinder 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 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. (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.
^ 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 satisfies the standard.
Over size (OS): 0.2 mm (0.008 inch)
Outer Diameter of Piston
Measure piston skirt diameter.
^ 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 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 "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 cylinders must also be bored.
^ Do not cut too much out of cylinder at a time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder.
^ 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 (1.1699 - 1.1106 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" it "A" and "B".
^ Taper is indicated by the difference in dimension between "A" and "B" it "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: Less than 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 pin)
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.
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 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.
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
^ Install the main bearings to the cylinder 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 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".
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 area A as shown.
^ 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)
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 gauge.
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 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.