Inspection and Replacement
INSPECTION
1. CLEAN CYLINDER BLOCK
a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
b) Using a soft brush and solvent, thoroughly clean the cylinder block.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 inch)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 94.990 - 95.003 mm (3.7400 - 3.7403 inch)
Maximum diameter: 95.06 mm (3.7425 inch)
If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.
6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter: 10.76 - 10.97 mm (0.4236 - 0.4319 inch)
Minimum outside diameter: 10.40 mm (0.4094 inch)
If the diameter is less than minimum, replace the bolt.
7. CLEAN PISTON
a) Using a gasket scraper, remove the carbon from the piston top.
b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
c) Using solvent and a brush, thoroughly clean the piston.
NOTICE: Do not use a wire brush.
8. INSPECT PISTON OIL CLEARANCE
a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 37.5 mm (1.47 inch) for from the piston head.
Piston diameter:
STD: 94.933 - 94.943 mm (3.7375 - 3.7379 inch)
O/S 0.50: 95.433 - 95.443 mm (3.7572 - 3.7576 inch)
b) Measure the cylinder bore diameter in the thrust directions. (See step 4.)
c) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.047 - 0.070 mm (0.0019 - 0.0028 inch)
If the oil clearance is greater than maximum, replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block.
HINT:
(Use new cylinder block)
Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.
9. INSPECT PISTON RING GROOVE CLEARANCE
Using a thickness gauge, measure the clearance between new piston ring and the wall of the piston ring groove.
Ring groove clearance:
No.1: 0.020 - 0.070 mm (0.0008 - 0.0028 inch)
No.2: 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
If the clearance is not as specified, replace the piston.
10. INSPECT PISTON RING END GAP
a) Insert the piston ring into the cylinder bore.
b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 125 mm (4.92 inch) from the top of the cylinder block.
c) Using a thickness gauge, measure the end gap.
Ring end gap:
No.1: 0.300 - 0.400 mm (0.0118 - 0.0157 inch)
No.2: 0.400 - 0.500 mm (0.0157 - 0.0197 inch)
If the end gap is not as specified, replace the piston ring. If the end gap is not as specified, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.
11. INSPECT PISTON PIN FIT
At 80 - 90°C (176 - 194°F), you should be able to push the piston pin into the piston pin hole with your thumb.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and thickness gauge, check the connecting rod alignment.
- Check for out-of-alignment.
Maximum out-of-alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If out-of-alignment is greater than maximum, replace the connecting rod assembly.
- Check for twist
Maximum twist: 0.15 mm (0.0059 in. ) per 100 mm (3.94 inch)
If twist is greater than maximum, replace the connecting rod assembly.
13. INSPECT PISTON PIN OIL CLEARANCE
a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 24.008 - 24.017 mm (0.9452 - 0.9455 inch)
b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 24.000 - 24.009 mm (0.9449 - 0.9452 inch)
c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 inch)
Maximum oil clearance: 0.015 mm (0.0006 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.
14. IF NECESSARY, REPLACE CONNECTING ROD BUSHING
a) Using SST and a press, press out the bushing.
SST 09207-76010
b) Align the oil holes of a new bushing and the connecting rod.
c) Using SST and a press, press in the bushing.
SST 09207-76010
d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step c) above) between the bushing and piston pin.
e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
15. INSPECT CONNECTING ROD BOLTS
a) Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread.
b) If the cap nut cannot be turned easily, measure the minimum outside diameter of the connecting rod bolt with vernier calipers.
Standard outside diameter: 7.80 - 7.90 mm (0.3071 - 0.3110 inch)
Minimum outside diameter: 7.60 mm (0.2992 inch)
HINT:
If the location of minimum diameter cannot be judged by visual inspection, measure the outer diameter at the location shown in the illustration.
If the outside diameter is less than limit, replace the connecting rod bolt and nut as a set.
16. INSPECT NO.1 (RH) AND NO.2 (LH) BALANCE SHAFTS
a) Using a cylinder gauge, measure the inside diameter of the balance shaft bearing.
Bearing inside diameter (from front side):
No.1 (RH): 38.025 - 38.045 mm (1.4970 - 1.4978 inch)
No.2 (LH): 37.525 - 37.545 mm (1.4774 - 1.4781 inch)
b) Using a micrometer, measure the diameter of the balance shaft main journals.
Main journal diameter (from front side):
No.1 (RH): 37.969 - 37.985 mm (1.4948 - 1.4955 inch)
No.2 (LH): 37.449 - 37.465 mm (1.4744 - 1.4750 inch)
c) Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement.
Standard oil clearance:
No.1 (RH): 0.040 - 0.076 mm (0.0016 - 0.0031 inch)
No.2 (LH): 0.060 - 0.096 mm (0.0024 - 0.0038 inch)
Maximum oil clearance: 0.15 mm (0.0059 inch)
If the clearance is greater than maximum, replace the cylinder block and balance shaft.
17. CYLINDER BORING
HINT:
- Bore all the 4 cylinders for the oversized piston outside diameter.
- Replace all the piston rings with ones to match the over sized pistons.
a) Keep the oversized pistons.
Oversized piston diameter:
O/S 0.50: 95.433 - 95.443 mm (3.7572 - 3.7576 inch)
b) Calculate amount to the bore cylinders.
(1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 37.5 mm (1.47 inch) from the piston head.
(2) Calculate the amount of each cylinder is to be rebored as follows:
Size to be rebored = P + C - H
P = Piston diameter
C = Piston clearance
0.047 - 0.070 mm (0.0019 - 0.0028 inch)
H = Allowance for honing 0.020 mm (0.0008 inch) or less
c) Bore and hone cylinder to the calculated dimensions.
Maximum honing: 0.02 mm (0.0008 inch)
NOTICE: Excessive honing will destroy the finished roundness.
18. INSPECT CRANKSHAFT FOR RUNOUT
a) Place the crankshaft on V-blocks.
b) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the crankshaft.
19. INSPECT MAIN JOURNALS AND CRANK PINS
a) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter:
STD:
No.3: 59.981 - 59.994 mm (2.2615 - 2.3620 inch)
Others: 59.987 - 60.000 mm (2.3617 - 2.3622 inch)
U/S 0.25:
No.3: 59.740 - 59.750 mm (2.3520 - 2.3524 inch)
Others: 59.745 - 59.755 mm (2.3522 - 2.3526 inch)
Crank pin diameter:
STD: 52.987 - 53.000 mm (2.0861 - 2.0866 inch)
U/S 0.25: 52.745 - 52.755 mm (2.0766 - 2.0770 inch)
If the diameter is not as specified, check the oil clearance. If necessary, grind or replace the crankshaft.
b) Check each main journal and crank pin for taper and out of-round as shown.
Maximum taper and out-of-round: 0.005 mm (0.0002 inch)
If the taper and out-of-round is greater than maximum, replace the crankshaft.
20. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the finished undersized diameter (See step 19.).
Install new main journal and/or crank pin undersized bearings.
21. REPLACE CRANKSHAFT FRONT OIL SEAL
22. REPLACE CRANKSHAFT REAR OIL SEAL
HINT: There are 2 methods (a)and b)) to replace the oil seal which are as follows:
a) If rear oil seal retainer is removed from cylinder block.
(1) Using a screwdriver and a hammer, tap out the oil seal.
(2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07150)
(3) Apply MP grease to the oil seal lip.
b) If rear oil seal retainer is installed to cylinder block.
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07150)