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).





- 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).






- If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the standard, 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.






Piston Pin Outer Diameter





Measure the outer diameter of piston pin with a micrometer.






Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)






- If oil clearance is out of the standard, replace piston and piston pin assembly.

PISTON RING SIDE CLEARANCE





- Measure the side clearance of piston ring and piston ring groove with a feeler gauge.






- 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





- Make sure that cylinder bore inner diameter is within the specification. Check "Cylinder Bore Inner Diameter".
- Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure piston ring end gap with a feeler gauge.






- If the measured value exceeds the limit, replace piston ring.

CONNECTING ROD BEND AND TORSION





- Check with a connecting rod aligner.






- If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER
- Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Disassembly And Assembly.





- Measure the inner diameter of connecting rod big end with an inside micrometer.






- If out of the standard, replace connecting rod assembly.

CONNECTING ROD SMALL END CLEARANCE

Connecting Rod Small End Inner Diameter





Measure the inner diameter of connecting rod small end with an inside micrometer.






Piston Pin Outer Diameter





Measure the outer diameter of piston pin with a micrometer.






Connecting Rod Small End Clearance
(Connecting rod small end clearance) = (Connecting rod small end inner diameter) - (Piston pin outer diameter)






- If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin assembly.
- If replacing connecting rod assembly, use "CONNECTING ROD BEARING OIL CLEARANCE" to select connecting rod bearing.

CYLINDER BLOCK TOP SURFACE 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 and a feeler gauge.






- If it exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INNER DIAMETER
- Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified torque. Disassembly And Assembly.









- Measure the position shown [5 mm (0.196 in) rearward from main bearing housing front side end surface) in the 2 directions as shown. The smaller one is the measured value.





- If out of the standard, replace cylinder block and main bearing caps as an assembly.

NOTE:
These components cannot be replaced as a single unit, because they were processed together.

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 the engine)

NOTE:
When determining cylinder bore grade, measure cylinder bore at "B" position.







- If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder block.

NOTE:
There is no service setting for oversized piston.

Piston Skirt Diameter





Measure the outer diameter of piston skirt with a micrometer.






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)






- If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block.

CRANKSHAFT MAIN JOURNAL DIAMETER





- Measure the outer diameter of crankshaft main journals with a micrometer (A).





- If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing.

CRANKSHAFT PIN JOURNAL DIAMETER





- Measure the outer diameter (Dp) of crankshaft pin journal with a micrometer.






- If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing.

OUT-OF-ROUND AND TAPER OF CRANKSHAFT





- Measure the dimensions at four different points as shown 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".






- 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.

CRANKSHAFT RUNOUT





- Place a V-block on a precise flat table to support the journals on the both end of crankshaft.
- Place a dial indicator (A) straight up on the No. 3 journal.
- While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading)






- If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
- Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Disassembly And Assembly.





- Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
- (Crankshaft pin journal diameter)






- If the clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. 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. Disassembly And Assembly.

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 to cylinder block and main bearing cap, and tighten main bearing cap bolts to the specified torque. Disassembly And Assembly.





- Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter)






- If the clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Service and Repair.

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 main bearing cap, and tighten main bearing cap bolts to the specified torque. Disassembly And Assembly.

CAUTION:
Never rotate crankshaft.





- Remove main 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".

MAIN BEARING CRUSH HEIGHT





- When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Disassembly And Assembly.






- 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 installed, the tip end of bearing must protrude. Disassembly And Assembly.






- If the standard is not met, replace connecting rod bearings.

MAIN BEARING CAP BOLT OUTER DIAMETER





- Measure the outer diameters ("d1", "d2") at two positions as shown.
- If reduction appears in a position other than "d2 ", regard it as "d2".






- If it exceeds the limit (a large difference in dimensions), replace main bearing cap bolt with a new one.

CONNECTING ROD CAP BOLT OUTER DIAMETER





- Measure the outer diameter "d" at position as shown.
- If reduction appears in a position other than "d", regard it as "d".






- When "d" falls below the limit (when it becomes thinner), replace connecting rod cap bolt with a new one.

FLYWHEEL DEFLECTION





- Measure the deflection of flywheel contact surface to clutch with a dial indicator.






- If measured value is out of the standard, replace flywheel.