PROCEDURE
INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY
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.
CLEAN CYLINDER BLOCK SUB-ASSEMBLY
Using a gasket scraper, remove all of the gasket material from the top surface of the cylinder block sub-assembly.
Using a soft brush and solvent, thoroughly clean the cylinder block sub-assembly.
INSPECT CYLINDER BLOCK FOR WARPAGE
Using a precision straightedge and feeler gauge, measure the warpage of the surface where the cylinder head gasket contacts the cylinder head sub-assembly.
Maximum Warpage |
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0.05 mm (0.00197 in.) |
If the warpage is more than the maximum, replace the cylinder block sub-assembly.
Visually check the cylinders for vertical scratches.
If deep scratches are present, replace the cylinder block sub-assembly.
INSPECT CYLINDER BORE
Using a cylinder gauge, measure the cylinder bore diameter at positions (A) and (B) in the thrust and axial directions.
*a | Front |
*b | Center |
*c | Thrust Direction |
*d | Axial Direction |
Standard Diameter |
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86.000 to 86.013 mm (3.3858 to 3.3863 in.) |
Maximum Diameter |
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86.213 mm (3.3942 in.) |
If the diameter is more than the maximum, replace the cylinder block sub-assembly.
Inspect the cylinder ridge.
If the wear is less than 0.2 mm (0.00787 in.), use a ridge reamer to grind the top of the cylinder.
CLEAN PISTON
Using a gasket scraper, remove all of the carbon from the top of the piston.
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
Using a soft brush and solvent, thoroughly clean the piston.
Do not use a wire brush.
INSPECT PISTON DIAMETER
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.
*1 | 10 mm |
Standard Piston Diameter |
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85.919 to 85.933 mm (3.3826 to 3.3832 in.) |
INSPECT PISTON OIL CLEARANCE
Measure the cylinder bore diameter in the thrust direction.
Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard Oil Clearance |
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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.
INSPECT RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
Standard Ring Groove Clearance | ||||||||
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If the ring groove clearance is not as specified, replace the piston.
INSPECT PISTON RING END GAP
Insert a piston ring into the cylinder bore.
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.
Using a feeler gauge, measure the end gap.
Standard End Gap | ||||||||
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Maximum End Gap | ||||||||
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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.
INSPECT PISTON PIN OIL CLEARANCE
Check each mark on the piston, piston pin and connecting rod.
*a | Front Mark | *b | Paint Mark |
*c | Piston Pin Hole Inside Diameter Mark | *d | Connecting Rod Bush Inside Diameter Mark |
Using a caliper gauge, measure the inside diameter of the piston pin hole.
Standard Piston Pin Hole Inside Diameter | ||||||||
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Using a micrometer, measure the piston pin diameter.
*a | 6 mm |
*b | 34.5 mm |
Standard Piston Pin Diameter | ||||||||
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Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Standard Bush Inside Diameter | ||||||||
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Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.
Standard Oil Clearance |
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0.005 to 0.013 mm (0.000197 to 0.000512 in.) |
Maximum Oil Clearance |
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0.05 mm (0.00197 in.) |
If the oil clearance is more than the maximum, replace the piston and piston pin as a set.
Subtract the piston pin diameter measurement from the connecting rod bush inside diameter measurement.
Standard Oil Clearance |
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0.015 to 0.023 mm (0.000591 to 0.000906 in.) |
Maximum Oil Clearance |
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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.
INSPECT CONNECTING ROD SUB-ASSEMBLY
Using a rod aligner and feeler gauge, check the connecting rod sub-assembly alignment.
Check for bend.
Maximum Bend |
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0.03 mm (0.00118 in.) per 100 mm (3.94 in.) |
If the bend is more than the maximum, replace the connecting rod.
Check for twist.
Maximum Twist |
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0.15 mm (0.00591 in.) per 100 mm (3.94 in.) |
If the twist is more than the maximum, replace the connecting rod.
INSPECT CONNECTING ROD THRUST CLEARANCE
Install the connecting rod with piston, piston ring set, connecting rod bearing and connecting rod cap.
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Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance |
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0.10 to 0.45 mm (0.00394 to 0.0177 in.) |
Maximum thrust clearance |
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0.55 mm (0.0217 in.) |
If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.
Remove the connecting rod cap, connecting rod bearings, piston ring set and connecting rod with piston.
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INSPECT CONNECTING ROD OIL CLEARANCE
Install the connecting rod bearings.
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Install the crankshaft bearings.
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Install the upper crankshaft thrust washers.
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Install the crankshaft.
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Clean the crank pin and connecting rod bearings.
Check the crank pin and connecting rod bearings for pitting and scratches.
Install the connecting rod.
Lay a strip of Plastigage on the crank pin.
*a | Plastigage |
Check that the front mark (protrusion) of the connecting rod cap is facing forward and install the connecting rod cap.
*a | Front Mark |
Uniformly tighten the 2 connecting rod bolts in several steps.
Do not turn the crankshaft.
Mark the front side of each connecting rod bolt with paint.
Further tighten the connecting rod bolts 90°.
*a | Paint Mark |
Front |
Check that the painted marks are now at a 90° angle to the front.
Do not turn the crankshaft.
*a | Paint Mark |
Front |
Remove the 2 connecting rod bolts.
Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
Keep the lower bearing inserted in the connecting rod cap.
Measure the Plastigage at its widest point.
*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 | - | - |
Front | - | - |
Standard Oil Clearance |
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0.024 to 0.042 mm (0.000945 to 0.00165 in.) |
Maximum Oil Clearance |
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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.
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 | ||||||||||||||||||||||||||||||||||||||||
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EXAMPLE:
Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")
Reference | ||||||||||||
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Connecting Rod Big End Inside Diameter | ||||||||||||
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Crankshaft Pin Diameter | ||||||||||||
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Standard Sized Bearing Center Wall Thickness | ||||||||||||
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Completely remove the Plastigage.
Remove the connecting rod.
Remove the crankshaft.
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Remove the upper crankshaft thrust washers.
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Remove the crankshaft bearings.
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Remove the connecting rod bearings.
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INSPECT CONNECTING ROD BOLT
Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.
*a | Measurement Area |
Standard Diameter |
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8.7 to 8.8 mm (0.343 to 0.346 in.) |
Minimum Diameter |
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8.5 mm (0.335 in.) |
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.
INSPECT CRANKSHAFT
Inspect for runout.
Place the crankshaft on V-blocks.
Using a dial indicator, measure the runout at the center journal.
Maximum Runout |
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0.04 mm (0.00157 in.) |
If the runout is more than the maximum, replace the crankshaft.
Inspect the main journals.
Using a micrometer, measure the diameter of each main journal.
Standard Journal Diameter |
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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.
Check each main journal for taper and out-of- round.
Maximum Taper and Out-of-round |
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0.005 mm (0.000197 in.) |
If the taper and out-of-round is more than the maximum, replace the crankshaft.
Inspect the crank pin.
Using a micrometer, measure the diameter of each crank pin.
Standard Crank Pin Diameter |
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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.
Check each crank pin for taper and out-of-round.
Maximum Taper and Out-of-round |
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0.003 mm (0.000118 in.) |
If the taper and out-of-round is more than the maximum, replace the crankshaft.
INSPECT CRANKSHAFT THRUST CLEARANCE
Install the crankshaft bearings, upper crankshaft thrust washers and crankshaft.
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Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard Thrust Clearance |
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0.04 to 0.24 mm (0.00157 to 0.00945 in.) |
Maximum Thrust Clearance |
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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 |
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1.93 to 1.98 mm (0.0760 to 0.0780 in.) |
Remove the crankshaft, upper crankshaft thrust washers and crankshaft bearings.
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INSPECT CRANKSHAFT OIL CLEARANCE
Install the crankshaft bearings.
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Install the upper crankshaft thrust washers.
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Clean each crankshaft main journal and crankshaft bearing.
Check each crankshaft main journal and crankshaft bearing for pitting and scratches.
If the crankshaft main journal or crankshaft bearing is damaged, replace the crankshaft bearing.
Place the crankshaft on the cylinder block sub-assembly.
Lay a strip of Plastigage across each crankshaft main journal.
*a | Plastigage |
Place the crankshaft bearing cap on the cylinder block sub-assembly.
Install the crankshaft bearing cap set bolts.
The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
Step 1:
Uniformly tighten the 10 crankshaft bearing cap set bolts in several steps, in the order shown in the illustration.
If any crankshaft bearing cap set bolt does not meet the torque specification, replace the crankshaft bearing cap set bolt.
Do not turn the crankshaft.
Step 2:
Mark the front of the crankshaft bearing cap set bolts with paint.
Tighten the crankshaft bearing cap set bolts 90°.
Check that the painted marks are now at a 90° angle to the front.
Uniformly tighten the 10 bolts in several steps, in the order shown in the illustration.
Remove the crankshaft bearing cap.
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Measure the Plastigage at its widest point.
*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 | ||||||
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Maximum Oil Clearance |
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0.10 mm (0.00394 in.) |
If the oil clearance is more than the maximum, replace the crankshaft bearings. If necessary, replace the crankshaft.
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 | ||||||||||||||||||||||||||||||||||||||||
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EXAMPLE:
Cylinder block "2" + Crankshaft "1" = Total number 3 (Use bearing "3")
Reference | ||||||||||||||
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Standard Cylinder Block Main Journal Bore Diameter | ||||||||||||||
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Standard Crankshaft Journal Diameter | ||||||||||||||
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Standard Sized Bearing Center Wall Thickness | ||||||||||||||
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Completely remove the Plastigage.
Remove the crankshaft.
Remove the upper crankshaft thrust washers.
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Remove the crankshaft bearings.
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INSPECT CRANKSHAFT BEARING CAP SET BOLT
Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.
*a | Measurement Area |
Standard Diameter |
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10.8 to 11.0 mm (0.425 to 0.433 in.) |
Minimum Diameter |
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10.4 mm (0.409 in.) |
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.