Inspection After Disassembly
dInspection After DisassemblyCRANKSHAFT END PLAY
^ Using a dial indicator, measure the clearance between the thrust bearings and the connecting rods when the crankshaft is moved from front to rear.
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit :0.30 mm (0.0118 inch)
^ If beyond the limit, replace the thrust bearings and measure again. If still beyond the limit, replace the crankshaft.
CONNECTING ROD SIDE CLEARANCE
^ Measure the side clearance between the connecting rod and crankshaft with a feeler gauge.
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit :0.40 mm (0.016 inch)
^ If beyond the limit, replace the connecting rod and measure again. If still beyond the limit, replace the crankshaft.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin Hole
^ Measure the inner diameter of piston pin hole "dp".
Standard diameter"dp"
Grade No. 0 : 21.993 - 21.999 mm (0.8659 - 0.8661 inch)
Grade No.1 : 21.999 - 22.005 mm (0.8661 - 0.8663 inch)
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin "DP".
Standard diameter"DP"
Grade No. 0 : 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No.1 : 21.995 - 22.001 mm (0.8659 - 0.8662 inch)
Piston and Piston Pin Interference Fit
Standard Interference Fit= "DP"-"dp"
Standard : 0.002 mm - 0.006 mm (0.0001 - 0.0002 inch)
^ If clearance is exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each part.
^ When replacing piston/piston pin assembly, refer to "PISTON-TO-CYLINDER BORE CLEARANCE".
PISTON RING SIDE CLEARANCE
^ Measure side clearance of piston ring and piston ring groove with feeler gauge.
Standard Side Clearance
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)
Maximum Limit
Top ring : 0.11 mm (0.0043 inch)
2nd ring : 0.1 mm (0.004 inch)
Oil ring :-
^ If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings, replace piston
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 it is in the middle of the cylinder bore and measure the end gap.
Standard
Top ring : 0.23 - 0.33 mm (0.0091 - 0.0130 inch)
2nd ring :0.33 - 0.48 mm (0.0130 - 0.0189 inch)
Oil ring :0.20 - 0.50 mm (0.0079 - 0.0197 inch)
Limit:
Top ring : 0.54 mm (0.0213 inch)
2nd ring :0.80 mm (0.0315 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
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 HOUSING DIAMETER (BIG END)
^ Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod nut to the specified torque, measure the connecting rod bearing housing big end inner diameter using an inside micrometer.
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 inch)
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
^ Measure inner diameter of piston pin bushing.
Standard
Grade No. 0 : 22.000 - 22.006 mm (0.8661 - 0.8664 inch)
Grade No.1 : 22.006 - 22.012 mm (0.8664 - 0.8666 inch)
Outer Diameter of Piston Pin
^ Measure outer diameter of piston pin.
Standard
Grade No. 0 : 21.989 - 21.995 mm (0.8657 - 0.8659 inch)
Grade No. 1 : 21.995 - 22.001 mm (0.8659 - 0.8662 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 pin)
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
Limit : 0.030 mm (0.0012 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 Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to "PISTON-TO-CYLINDER BORE CLEARANCE".
^ If replacing the connecting rod assembly, refer to "CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)".
Factory installed parts grading:
^ Service parts apply only to grade 0.
CYLINDER BLOCK DISTORTION
^ Using a scraper, remove any old gasket material on the cylinder block surface, and remove any oil, scale, carbon, or other contamination.
CAUTION: Be careful not to allow gasket flakes to enter the oil or coolant passages.
^ Measure the distortion on the block upper face at different points in six directions.
Distortion limit : 0.10 mm (0.0039 inch)
^ If out of specification, resurface the cylinder block. The allowable amount of resurfacing is dependent on the amount of any cylinder head resurfacing. The resurfacing limit is [amount of cylinder head resurfacing] + [amount of cylinder head resurfacing] = 0.2 mm (0.008 inch).
Cylinder block height : 214.95 - 215.05 mm (8.4626 - 8.4665 inch)
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 : 63.993 - 64.017 mm (2.5194 - 2.5203 inch)
^ If out of the standard, replace the cylinder block and main bearing caps as an assembly.
NOTE: These components cannot be replaced individually, since they were processed together.
PISTON-TO-CYLINDER BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. The X axis is in the longitudinal direction of the engine.
Cylinder bore inner diameter
If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
Out-of-round (Difference between, X - Y) : less than 0.015 mm (0.0006 inch)
Taper (Difference between, C - A) : less than 0.015 mm (0.0006 inch)
2. Check for scratches and seizure. If seizure is found, hone it.
^ If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter.
Piston diameter "A" : Refer to "PISTON, PISTON RING AND PISTON PIN".
Measuring point "a" (distance from the top) :41.0 mm (1.614 inch)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance at "B" : 0.010 - 0.030 mm (0.0004 - 0.0012 inch)
^ The piston-to-bore clearance is measured at the "B" level in the cylinder as shown.
5. Determine piston oversize according to amount of cylinder wear.
^ Oversize pistons are available for service.
^ If oversize piston is used, use it for all cylinders with oversize piston ring. Refer to "PISTON, PISTON RING AND PISTON PIN".
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A".
Rebored size calculation where, : D = A + B - C
D : Bored diameter
A : Piston diameter as measured
B : Piston-to-bore clearance
C : Honing allowance 0.02 mm (0.0008 inch)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted after boring.
8. 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.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. 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. Refer to "OUT-OF-ROUND AND TAPER OF CRANKSHAFT".
OUTER DIAMETER OF CRANKSHAFT PIN
Measure outer diameter of crankshaft pin. Refer to "OUT-OF-ROUND AND TAPER OF CRANKSHAFT"
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
^ Check the crankshaft main and pin journals for scoring, wear, or cracks. Measure the journals for taper and out-of-round.
Standard
Out-of-round (difference between, X - Y) : 0.002 mm (0.0001 inch)
Taper (difference between, A - B) : 0.002 mm (0.0001 inch)
CRANKSHAFT RUNOUT
^ Place a V-block on a precise flat table to support the journals on the 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.
Runout limit (total indicator reading) : less than 0.10 mm (0 0039 inch)
OIL CLEARANCE OF CONNECTING ROD BEARING
Method by Calculation
1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to "ASSEMBLY".
3. Measure the inner diameter "C" of each connecting rod (big end) as shown.
4. Measure the outer diameter "Dp" of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 inch)
Limit : 0.070 mm (0.0028 inch)
6. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings. Refer to "HOW TO SELECT CONNECTING ROD BEARINGS". How to Select Connecting Rod Bearings
Method of Using Plastigage
^ Remove oil and dust on the 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 the connecting rod bearings to the connecting rod cap, and tighten the connecting rod nuts 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 repair limit is same as that described in, "Method by Calculation".
OIL CLEARANCE OF MAIN BEARING
Method by Calculation
1. Install the main bearings to the cylinder block and bearing cap. Refer to "ASSEMBLY".
2. Calculate the main bearing clearance. (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal)
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 inch)
Limit :0.065 mm (0.0026 inch)
3. If the calculated clearance exceeds the specified limit, replace the bearings. Refer to "HOW TO SELECT MAIN BEARINGS". How to Select Main Bearings
Method of Using Plastigage
^ Remove oil and dust on the 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 the main bearings and main bearing caps. Refer to "ASSEMBLY".
CAUTION: Never rotate the crankshaft.
^ Remove the main bearing caps and bearings, and using the scale on the Plastigage bag, measure the Plastigage width.
NOTE: The procedure when the measured value exceeds the repair limit is same as that described in "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 the bearing must protrude. Refer to "ASSEMBLY" for tightening procedure.
Standard : There must be a crush height.
^ If the standard is not met, replace main bearings.
CRUSH HEIGHT OF CONNECTING ROD BEARING
^ When the connecting rod bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of the bearing must protrude. Refer to "ASSEMBLY" for tightening procedure.
Standard : There must be a crush height. If the standard is not met, replace connecting rod bearings.
OUTER DIAMETER OF MAIN BEARING CAP BOLTS
^ Measure outer diameters (d1, d2) at two positions as shown.
^ Measure d2 at a point with A.
Limit : 0.11 mm (0.0051 inch)
^ When the value of d1 - d2 exceeds the limit (a large difference in dimensions) replace the bolt with a new one.
OUTER DIAMETER OF CONNECTING ROD BOLTS
^ Measure outer diameter d as shown.
Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit : 7.75 mm (0.3051 inch)
^ When the value of d exceeds the limit (when it becomes thinner) replace the bolt with a new one.
DRIVE PLATE RUNOUT (A/T)
Runout (Total Indicator Reading):
Drive plate (A/T) : less than 0.15 mm (0.0059 inch)
CAUTION:
^ The signal plate is built into the drive assembly. Be careful not to damage the signal plate, particularly the teeth.
^ Check the drive plate and signal plate for deformation or cracks.
^ Keep any magnetized objects away from the signal plate, particularly the teeth.
FLYWHEEL RUNOUT (M/T)
NOTE:
^ This inspection is for double mass flywheel only.
^ Do not disassemble the double mass flywheel.
Flywheel Deflection
^ Measure the deflection of the flywheel contact surface to the clutch with a dial gauge.
^ Measure the deflection at 210 mm (8.27 inch) diameter.
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 Around in Rotation Direction
Check the movement amount with 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 the bolt at a force of 9.8 Nm (1 kg-m, 87 inch lbs.) to keep it from loosening.
2. Put a mating mark on the circumference 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 transaxle side.
4. Measure dimensions of movement amounts A and B on the circumference of the flywheel on the transaxle side.
Flywheel movement in rotation direction : 24 mm (0.94 inch) or less
^ When the measured value exceeds the standard, replace the flywheel.
OIL JET
^ Check nozzle for deformation and damage.
^ Blow compressed air from nozzle, and check for clogs.
^ If it is not satisfied, replace oil jet.
OIL JET RELIEF VALVE
^ Using a clean plastic stick, press check valve in oil jet relief valve. Make sure that valve moves smoothly with proper reaction force.
^ If it is not satisfied, replace oil jet relief valve.