БЛОК ЦИЛИНДРОВ ПРОВЕРКА

PROCEDURE

  1. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. Check the No. 1 oil nozzle sub-assemblies for damage or clogging.

      If there is damage or clogging, replace the No. 1 oil nozzle sub-assemblies.

  2. CLEAN CYLINDER BLOCK SUB-ASSEMBLY

    1. Using a gasket scraper, remove all of the gasket material from the top surface of the cylinder block sub-assembly.

    2. Using a soft brush and solvent, thoroughly clean the cylinder block sub-assembly.

  3. INSPECT CYLINDER BLOCK FOR WARPAGE

    1. Using a precision straightedge and feeler gauge, measure the warpage of the surface where the cylinder head gasket contacts the cylinder head sub-assembly.

      A012M0A
      Maximum Warpage
      0.05 mm (0.00197 in.)

      If the warpage is more than the maximum, replace the cylinder block sub-assembly.

    2. Visually check the cylinders for vertical scratches.

      If deep scratches are present, replace the cylinder block sub-assembly.

  4. INSPECT CYLINDER BORE

    1. Using a cylinder gauge, measure the cylinder bore diameter at positions (A) and (B) in the thrust and axial directions.

      A012LTQC01
      *a Front
      *b Center
      *c Thrust Direction
      *d Axial Direction
      Standard Diameter
      86.000 to 86.013 mm (3.3858 to 3.3863 in.)
      Maximum Diameter
      86.213 mm (3.3942 in.)

      If the diameter is more than the maximum, replace the cylinder block sub-assembly.

    2. Inspect the cylinder ridge.

      A012HHE

      If the wear is less than 0.2 mm (0.00787 in.), use a ridge reamer to grind the top of the cylinder.

  5. CLEAN PISTON

    1. Using a gasket scraper, remove all of the carbon from the top of the piston.

    2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.

    3. Using a soft brush and solvent, thoroughly clean the piston.

      Note:

      Do not use a wire brush.

  6. INSPECT PISTON DIAMETER

    1. Using a micrometer, measure the piston diameter at right angles to the piston center line at a position 10 mm (0.394 in.) from the bottom of the piston.

      A012JXSN01
      Table 1.
      *1 10 mm
      Standard Piston Diameter
      85.919 to 85.933 mm (3.3826 to 3.3832 in.)

  7. INSPECT PISTON OIL CLEARANCE

    1. Measure the cylinder bore diameter in the thrust direction.

    2. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

      Standard Oil Clearance
      0.067 to 0.094 mm (0.00264 to 0.00370 in.)

      If the piston oil clearance is not as specified, replace all pistons. If necessary, replace the cylinder block sub-assembly.

  8. INSPECT RING GROOVE CLEARANCE

    1. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

      Standard Ring Groove Clearance
      Ring Specified Condition
      No. 1 Compression Ring 0.095 to 0.135 mm (0.00374 to 0.00531 in.)
      No. 2 Compression Ring 0.08 to 0.12 mm (0.00315 to 0.00472 in.)
      Oil Ring 0.03 to 0.07 mm (0.00118 to 0.00276 in.)

      If the ring groove clearance is not as specified, replace the piston.

  9. INSPECT PISTON RING END GAP

    1. Insert a piston ring into the cylinder bore.

    2. Using a piston, push the piston ring a little beyond the bottom of the ring travel 115 mm (4.53 in.) from the top of the cylinder block sub-assembly.

    3. Using a feeler gauge, measure the end gap.

      Standard End Gap
      Ring Specified Condition
      No. 1 Compression Ring 0.22 to 0.32 mm (0.00866 to 0.0126 in.)
      No. 2 Compression Ring 0.93 to 1.08 mm (0.0366 to 0.0425 in.)
      Oil Ring 0.1 to 0.40 mm (0.00394 to 0.0157 in.)
      Maximum End Gap
      Ring Specified Condition
      No. 1 Compression Ring 0.92 mm (0.0362 in.)
      No. 2 Compression Ring 1.68 mm (0.0661 in.)
      Oil Ring 1.00 mm (0.0394 in.)

      If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block sub-assembly.

  10. INSPECT PISTON PIN OIL CLEARANCE

    1. Check each mark on the piston, piston pin and connecting rod.

      A012MSSC01
      *a Front Mark *b Paint Mark
      *c Piston Pin Hole Inside Diameter Mark *d Connecting Rod Bush Inside Diameter Mark

    2. Using a caliper gauge, measure the inside diameter of the piston pin hole.

      A012L97
      Standard Piston Pin Hole Inside Diameter
      Mark Specified Condition
      A 29.009 to 29.013 mm (1.1421 to 1.1422 in.)
      B 29.013 to 29.017 mm (1.1422 to 1.1424 in.)
      C 29.017 to 29.021 mm (1.1424 to 1.1426 in.)

    3. Using a micrometer, measure the piston pin diameter.

      A012IC6N04
      Table 2.
      *a 6 mm
      *b 34.5 mm
      Standard Piston Pin Diameter
      Mark (Paint Color) Specified Condition
      A (White) 29.000 to 29.004 mm (1.1417 to 1.1419 in.)
      B (Pink) 29.004 to 29.008 mm (1.1419 to 1.1420 in.)
      C (Blue) 29.008 to 29.012 mm (1.1420 to 1.1422 in.)

    4. Using a caliper gauge, measure the inside diameter of the connecting rod bush.

      Standard Bush Inside Diameter
      Mark Specified Condition
      A 29.019 to 29.023 mm (1.1425 to 1.1426 in.)
      B 29.023 to 29.027 mm (1.1426 to 1.1428 in.)
      C 29.027 to 29.031 mm (1.1428 to 1.1430 in.)

    5. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

      Standard Oil Clearance
      0.005 to 0.013 mm (0.000197 to 0.000512 in.)
      Maximum Oil Clearance
      0.05 mm (0.00197 in.)

      If the oil clearance is more than the maximum, replace the piston and piston pin as a set.

    6. Subtract the piston pin diameter measurement from the connecting rod bush inside diameter measurement.

      Standard Oil Clearance
      0.015 to 0.023 mm (0.000591 to 0.000906 in.)
      Maximum Oil Clearance
      0.025 mm (0.000984 in.)

      If the oil clearance is more than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston with pin as a set.

  11. INSPECT CONNECTING ROD SUB-ASSEMBLY

    1. Using a rod aligner and feeler gauge, check the connecting rod sub-assembly alignment.

      1. Check for bend.

        A012K1I
        Maximum Bend
        0.03 mm (0.00118 in.) per 100 mm (3.94 in.)

        If the bend is more than the maximum, replace the connecting rod.

      2. Check for twist.

        A012KGH
        Maximum Twist
        0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

        If the twist is more than the maximum, replace the connecting rod.

  12. INSPECT CONNECTING ROD THRUST CLEARANCE

    1. Install the connecting rod with piston, piston ring set, connecting rod bearing and connecting rod cap.

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    2. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      A012N63
      Standard thrust clearance
      0.10 to 0.45 mm (0.00394 to 0.0177 in.)
      Maximum thrust clearance
      0.55 mm (0.0217 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

    3. Remove the connecting rod cap, connecting rod bearings, piston ring set and connecting rod with piston.

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  13. INSPECT CONNECTING ROD OIL CLEARANCE

    1. Install the connecting rod bearings.

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    2. Install the crankshaft bearings.

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    3. Install the upper crankshaft thrust washers.

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    4. Install the crankshaft.

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    5. Clean the crank pin and connecting rod bearings.

    6. Check the crank pin and connecting rod bearings for pitting and scratches.

    7. Install the connecting rod.

    8. Lay a strip of Plastigage on the crank pin.

      A012G0RC07
      *a Plastigage

    9. Check that the front mark (protrusion) of the connecting rod cap is facing forward and install the connecting rod cap.

      A012LE0C05
      *a Front Mark

    10. Uniformly tighten the 2 connecting rod bolts in several steps.

      A012IJN
      Момент затяжки
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      Note:

      Do not turn the crankshaft.

    11. Mark the front side of each connecting rod bolt with paint.

    12. Further tighten the connecting rod bolts 90°.

      A012IATC01
      *a Paint Mark
      A012M0O Front

    13. Check that the painted marks are now at a 90° angle to the front.

      Note:

      Do not turn the crankshaft.

      A012LU2C01
      *a Paint Mark
      A012M0O Front

    14. Remove the 2 connecting rod bolts.

      A012HUT

    15. Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tip:

      Keep the lower bearing inserted in the connecting rod cap.

      A012GUZ

    16. Measure the Plastigage at its widest point.

      A012LSPC04
      *a No. 1 *b No. 2
      *c No. 3 *d No. 4
      *e Mark 1, 2, or 3 *f Mark 1, 2, 3, 4 or 5
      *g Plastigage - -
      A012M0O Front - -
      Standard Oil Clearance
      0.024 to 0.042 mm (0.000945 to 0.00165 in.)
      Maximum Oil Clearance
      0.070 mm (0.00276 in.)

      If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

      Tip:

      If using a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearings by adding together the numbers imprinted on the crankshaft and connecting rod, and then selecting bearings with the same number as the total. There are 5 sizes of standard bearings, marked 1, 2, 3, 4 or 5.

      Standard Bearing Chart
      Item Number Mark
      Connecting rod cap 3 2 3 1 2 3 1 2 1
      Crankshaft 2 2 1 2 1 0 1 0 0
      Use bearing 5 4 3 2 1

      EXAMPLE:

      Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")

      Reference
      Connecting Rod Big End Inside Diameter
      Mark Specified Condition
      1 53.000 to 53.006 mm (2.0866 to 2.0868 in.)
      2 53.006 to 53.012 mm (2.0868 to 2.0871 in.)
      3 53.012 to 53.018 mm (2.0871 to 2.0873 in.)
      Crankshaft Pin Diameter
      Mark Specified Condition
      0 49.994 to 50.000 mm (1.9683 to 1.9685 in.)
      1 49.988 to 49.994 mm (1.9680 to 1.9683 in.)
      2 49.982 to 49.988 mm (1.9678 to 1.9680 in.)
      Standard Sized Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.485 to 1.488 mm (0.0585 to 0.0586 in.)
      2 1.488 to 1.491 mm (0.0586 to 0.0587 in.)
      3 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
      4 1.494 to 1.497 mm (0.0588 to 0.0589 in.)
      5 1.497 to 1.500 mm (0.0589 to 0.0591 in.)

    17. Completely remove the Plastigage.

    18. Remove the connecting rod.

    19. Remove the crankshaft.

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    20. Remove the upper crankshaft thrust washers.

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    21. Remove the crankshaft bearings.

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    22. Remove the connecting rod bearings.

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  14. INSPECT CONNECTING ROD BOLT

    1. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

      A012LF5C04
      *a Measurement Area
      Standard Diameter
      8.7 to 8.8 mm (0.343 to 0.346 in.)
      Minimum Diameter
      8.5 mm (0.335 in.)
      Tip:

      • Diameter measurements should be done at several points.

      • If there is any thread deformation, replace the connecting rod bolt with a new one.

      • If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.

  15. INSPECT CRANKSHAFT

    1. Inspect for runout.

      1. Place the crankshaft on V-blocks.

      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout
        0.04 mm (0.00157 in.)

        If the runout is more than the maximum, replace the crankshaft.

    2. Inspect the main journals.

      1. Using a micrometer, measure the diameter of each main journal.

        Standard Journal Diameter
        58.982 to 59.000 mm (2.3221 to 2.3228 in.)

        If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

      2. Check each main journal for taper and out-of- round.

        A012JT0
        Maximum Taper and Out-of-round
        0.005 mm (0.000197 in.)

        If the taper and out-of-round is more than the maximum, replace the crankshaft.

    3. Inspect the crank pin.

      1. Using a micrometer, measure the diameter of each crank pin.

        Standard Crank Pin Diameter
        49.982 to 50.000 mm (1.9678 to 1.9685 in.)

        If the crank pin diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

      2. Check each crank pin for taper and out-of-round.

        A012F66
        Maximum Taper and Out-of-round
        0.003 mm (0.000118 in.)

        If the taper and out-of-round is more than the maximum, replace the crankshaft.

  16. INSPECT CRANKSHAFT THRUST CLEARANCE

    1. Install the crankshaft bearings, upper crankshaft thrust washers and crankshaft.

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    2. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      A012HI2
      Standard Thrust Clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum Thrust Clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

      Standard Thrust Washer Thickness
      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

    3. Remove the crankshaft, upper crankshaft thrust washers and crankshaft bearings.

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  17. INSPECT CRANKSHAFT OIL CLEARANCE

    1. Install the crankshaft bearings.

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    2. Install the upper crankshaft thrust washers.

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    3. Clean each crankshaft main journal and crankshaft bearing.

    4. Check each crankshaft main journal and crankshaft bearing for pitting and scratches.

      Tip:

      If the crankshaft main journal or crankshaft bearing is damaged, replace the crankshaft bearing.

    5. Place the crankshaft on the cylinder block sub-assembly.

    6. Lay a strip of Plastigage across each crankshaft main journal.

      A012G0RC08
      *a Plastigage

    7. Place the crankshaft bearing cap on the cylinder block sub-assembly.

    8. Install the crankshaft bearing cap set bolts.

      Tip:

      The crankshaft bearing cap set bolts are tightened in 2 progressive steps.

    9. Step 1:

      1. Uniformly tighten the 10 crankshaft bearing cap set bolts in several steps, in the order shown in the illustration.

        A012IPIN01
        Момент затяжки
        60 N*m  { 612 kgf*cm, 44 ft.*lbf }
        Tip:

        If any crankshaft bearing cap set bolt does not meet the torque specification, replace the crankshaft bearing cap set bolt.

        Note:

        Do not turn the crankshaft.

    10. Step 2:

      1. Mark the front of the crankshaft bearing cap set bolts with paint.

      2. Tighten the crankshaft bearing cap set bolts 90°.

      3. Check that the painted marks are now at a 90° angle to the front.

    11. Uniformly tighten the 10 bolts in several steps, in the order shown in the illustration.

      A012KG6N01
      Момент затяжки
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    12. Remove the crankshaft bearing cap.

      Click hereНажмите здесь

    13. Measure the Plastigage at its widest point.

      A012G3PC04
      *a No. 1 *b No. 2
      *c No. 3 *d No. 4
      *e No. 5 *f Mark 1, 2, 3, 4 or 5
      *g Plastigage - -
      Standard Oil Clearance
      Journal Specified Condition
      No. 3 0.020 to 0.038 mm (0.000787 to 0.00150 in.)
      Others 0.014 to 0.032 mm (0.000551 to 0.00126 in.)
      Maximum Oil Clearance
      0.10 mm (0.00394 in.)

      If the oil clearance is more than the maximum, replace the crankshaft bearings. If necessary, replace the crankshaft.

      Tip:

      If using a standard bearing, replace it with one with the same number. If the number of the bearing cannot be determined, select the correct crankshaft bearing by adding together the numbers imprinted on the cylinder block sub-assembly and crankshaft, and then selecting the crankshaft bearing with the same number as the total.

      There are 6 sizes of standard bearings, marked 0, 1, 2, 3, 4 or 5.

      Standard Bearing Chart
      Table 3. No. 3 Journal
      Item Number Mark
      Cylinder block 2 2 1 2 1 0 1 0 0
      Crankshaft 2 1 2 0 1 2 0 1 0
      Use bearing 4 3 2 1 0
      Table 4. Other Journals
      Item Number Mark
      Cylinder block 3 3 2 3 2 1 2 1 1
      Crankshaft 2 1 2 0 1 2 0 1 0
      Use bearing 5 4 3 2 1

      EXAMPLE:

      Cylinder block "2" + Crankshaft "1" = Total number 3 (Use bearing "3")

      Reference
      Standard Cylinder Block Main Journal Bore Diameter
      Table 5. No. 3 Journal
      Mark Specified Condition
      0 63.000 to 63.006 mm (2.4803 to 2.4805 in.)
      1 63.006 to 63.012 mm (2.4805 to 2.4808 in.)
      2 63.012 to 63.018 mm (2.4808 to 2.4810 in.)
      Table 6. Other Journals
      Mark Specified Condition
      1 63.000 to 63.006 mm (2.4803 to 2.4805 in.)
      2 63.006 to 63.012 mm (2.4805 to 2.4808 in.)
      3 63.012 to 63.018 mm (2.4808 to 2.4810 in.)
      Standard Crankshaft Journal Diameter
      Mark Specified Condition
      0 58.994 to 59.000 mm (2.3226 to 2.3228 in.)
      1 58.988 to 58.994 mm (2.3224 to 2.3226 in.)
      2 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
      Standard Sized Bearing Center Wall Thickness
      Mark Specified Condition
      0 1.987 to 1.990 mm (0.0782 to 0.0783 in.)
      1 1.990 to 1.993 mm (0.0783 to 0.0785 in.)
      2 1.993 to 1.996 mm (0.0785 to 0.0786 in.)
      3 1.996 to 1.999 mm (0.0786 to 0.0787 in.)
      4 1.999 to 2.002 mm (0.0787 to 0.0788 in.)
      5 2.002 to 2.005 mm (0.0788 to 0.0789 in.)

    14. Completely remove the Plastigage.

    15. Remove the crankshaft.

    16. Remove the upper crankshaft thrust washers.

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    17. Remove the crankshaft bearings.

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  18. INSPECT CRANKSHAFT BEARING CAP SET BOLT

    1. Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

      A012NCYC04
      *a Measurement Area
      Standard Diameter
      10.8 to 11.0 mm (0.425 to 0.433 in.)
      Minimum Diameter
      10.4 mm (0.409 in.)
      Tip:

      • If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt with a new one. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.