БЛОК ЦИЛИНДРОВ ПРОВЕРКА

PROCEDURE

  1. INSPECT CONNECTING ROD THRUST CLEARANCE

    1. Install the connecting rod cap.

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

      A012JUY
      Standard thrust clearance
      0.16 to 0.36 mm (0.00630 to 0.0142 in.)
      Maximum thrust clearance
      0.36 mm (0.0142 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod sub-assembly.

  2. INSPECT CONNECTING ROD OIL CLEARANCE

    1. Clean the connecting rod bearing and connecting rod crank pin.

    2. Check that the connecting rod bearing and crank pin are not excessively worn or scratched.

    3. Lay a strip of Plastigage across the crank pin.

      A012GOVC03
      *a Plastigage

    4. Install the connecting rod cap.

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      Note:

      Do not turn the crankshaft.

    5. Remove the connecting rod cap.

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    6. Measure the Plastigage at its widest point.

      A012FSH
      Standard oil clearance
      0.014 to 0.038 mm (0.000551 to 0.00150 in.)
      Maximum oil clearance
      0.065 mm (0.00256 in.)
      Note:

      Completely remove the Plastigage after the measurement.

      If the oil clearance is greater than the maximum, replace the connecting rod bearings.

      A012F6TC03
      *a Front Mark
      *b Number Mark
      Table 1. Reference
      Number Mark

      Connecting Rod

      Diameter

      mm (in.)

      Center Bearing

      Thickness

      mm (in.)

      Oil Clearance

      mm (in.)
      1

      47.000 to 47.008

      (1.85039 to 1.85071)

      1.489 to 1.493

      (0.05862 to 0.05878)

      0.014 to 0.038

      (0.000551 to 0.00150)
      2

      47.009 to 47.016

      (1.85075 to 1.85102)

      1.494 to 1.497

      (0.05882 to 0.05894)
      3

      47.017 to 47.024

      (1.85106 to 1.85134)

      1.498 to 1.501

      (0.05898 to 0.05909)

  3. INSPECT CRANKSHAFT THRUST CLEARANCE

    1. Install the crankshaft.

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

      A012LH9
      Standard thrust clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)
      Thrust washer thickness
      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

      If the thrust clearance is greater than the maximum, replace the upper crankshaft thrust washers or crankshaft.

  4. INSPECT CYLINDER BLOCK FOR FLATNESS

    1. Using a precision straightedge and feeler gauge, measure the warpage of the top surface of the cylinder block sub-assembly.

      A012MWN
      Maximum warpage
      0.05 mm (0.00197 in.)

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

  5. INSPECT CYLINDER BORE

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

      A012IGGC01
      *a Thrust Direction
      *b Axial Direction
      *c Center
      A012M0O Front
      Standard diameter
      73.000 to 73.013 mm (2.8740 to 2.8745 in.)
      Maximum diameter
      73.13 mm (2.8791 in.)

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

  6. INSPECT PISTON DIAMETER

    1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, and at a position 50.4 mm (1.98 in.) from the piston end.

      A012JZMN01
      Table 2.
      *1 50.4 mm
      Standard piston diameter
      72.936 to 72.988 mm (2.8715 to 2.8735 in.)

      If the piston diameter is not as specified, replace the piston with pin sub-assembly.

  7. INSPECT PISTON OIL CLEARANCE

    1. Subtract the piston diameter measurement from the cylinder bore minimum diameter measurement to calculate the piston oil clearance.

      Standard oil clearance
      0.012 to 0.077 mm (0.000472 to 0.00303 in.)
      Maximum oil clearance
      0.08 mm (0.00315 in.)

      If the piston oil clearance is greater than the maximum, replace the piston with pin sub-assembly or cylinder block sub-assembly.

  8. INSPECT RING GROOVE CLEARANCE

    1. Using a feeler gauge, measure the clearance between the piston ring and ring groove all around the piston.

      A012I1F
      Standard Ring Groove Clearance
      Ring

      Standard

      mm (in.)
      No. 1

      0.110 to 0.150

      (0.00433 to 0.00591)
      No. 2

      0.075 to 0.110

      (0.00295 to 0.00433)
      Oil

      0.030 to 0.070

      (0.00118 to 0.00276)

      If the clearance is not as specified, replace the piston with pin sub-assembly or piston ring set.

  9. INSPECT PISTON RING END GAP

    1. Using a piston, push the piston ring until it is 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.

      A012GYHC01
      *1 Piston Ring

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

      A012MV0
      Standard End Gap
      Ring

      Standard

      mm (in.)

      Maximum

      mm (in.)
      No. 1

      0.17 to 0.27

      (0.00669 to 0.0106)

      0.42

      (0.0165)
      No. 2

      0.61 to 0.71

      (0.0240 to 0.0280)

      0.80

      (0.0315)
      Oil

      0.20 to 0.40

      (0.00787 to 0.0157)

      0.70

      (0.0276)

      If the end gap is greater than the maximum, replace the piston ring set.

  10. INSPECT PISTON PIN OIL CLEARANCE

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

      A012FYXC01
      *a Mark
      Standard Piston Pin Hole Inside Diameter
      Item

      Specified Condition

      mm (in.)
      Mark A

      27.019 to 27.023

      (1.06374 to 1.06390)
      Mark B

      27.023 to 27.027

      (1.06390 to 1.06405)
      Mark C

      27.027 to 27.031

      (1.06405 to 1.06421)

    2. Using a micrometer, measure the diameter of the piston pin.

      A012ISKC01
      *a Mark
      Standard Piston Pin Diameter
      Item

      Specified Condition

      mm (in.)
      Mark A

      27.008 to 27.012

      (1.06330 to 1.06346)
      Mark B

      27.012 to 27.016

      (1.06346 to 1.06362)
      Mark C

      27.016 to 27.020

      (1.06362 to 1.06378)
      Note:

      Do not change the combinations of the pistons and piston pins so that they can be returned to their original locations when reassembling.

    3. Using a caliper gauge, measure the inside diameter of the connecting rod sub-assembly.

      A012LG1C01
      *a Mark
      Standard Connecting Rod Inside Diameter
      Item

      Specified Condition

      mm (in.)
      Mark A

      27.022 to 27.026

      (1.06386 to 1.06401)
      Mark B

      27.026 to 27.030

      (1.06401 to 1.06417)
      Mark C

      27.030 to 27.034

      (1.06417 to 1.06433)

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

      Standard oil clearance
      0.007 to 0.015 mm (0.000276 to 0.000591 in.)
      Maximum oil clearance
      0.05 mm (0.00197 in.)

      If the oil clearance is greater than the maximum, replace the piston with pin sub-assembly.

    5. Subtract the piston pin diameter measurement from the connecting rod sub-assembly inside diameter measurement.

      Standard oil clearance
      0.010 to 0.018 mm (0.000394 to 0.000709 in.)
      Maximum oil clearance
      0.05 mm (0.00197 in.)

      If the oil clearance is greater than the maximum, replace the connecting rod sub-assembly and piston with pin sub-assembly as a set.

  11. INSPECT CONNECTING ROD SUB-ASSEMBLY

    1. A012KWG

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

      1. Check for misalignment.

        Maximum misalignment
        0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

        If the misalignment is greater than the maximum, replace the connecting rod sub-assembly.

      2. Check for twist.

        A012IQC
        Maximum twist
        0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

        If the twist is greater than the maximum, replace the connecting rod sub-assembly.

  12. INSPECT CONNECTING ROD BOLT

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

      A012HN9C06
      *a Measurement Area
      Standard diameter
      6.6 to 6.7 mm (0.260 to 0.264 in.)
      Minimum diameter
      6.4 mm (0.252 in.)
      Tip:

      Diameter measurements should be done at several points.

      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.

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

  13. INSPECT CRANKSHAFT

    1. Inspect for runout.

      A012G7P

      1. Using a dial indicator and V-blocks, measure the runout of the crankshaft.

        Maximum runout
        0.015 mm (0.000591 in.)

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

    2. Inspect the main journals.

      A012M0U

      1. Using a micrometer, measure the diameter of each main journal as shown in the illustration.

        Standard diameter
        45.988 to 46.000 mm (1.8105 to 1.8110 in.)

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

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

        Maximum taper and out-of-round
        0.02 mm (0.000787 in.)

        If the taper and out-of-round are greater than the maximum, replace the crankshaft.

      3. Using a micrometer, measure the diameter of each crank pin as shown in the illustration.

        A012KQF
        Standard diameter
        43.992 to 44.000 mm (1.7320 to 1.7323 in.)

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

      4. Check the taper and out-of-round of each crank pin.

        Maximum taper and out-of-round
        0.02 mm (0.000787 in.)

        If the taper and out-of-round are greater than the maximum, replace the crankshaft.

  14. INSPECT CRANKSHAFT BEARING CAP SET BOLT

    1. Using a vernier caliper, measure the diameter of the crankshaft bearing cap set bolt at several points within the area shown in the illustration.

      A012FDQC02
      *a Measurement Area
      Standard diameter
      10.8 to 11.0 mm (0.425 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)

      If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt.

      Tip:

      Diameter measurements should be done at several points.

      If the diameter is less than the minimum, replace the crankshaft bearing cap 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 bolt with a new one.

  15. INSPECT CRANKSHAFT OIL CLEARANCE

    1. Install the crankshaft bearing.

      Click hereНажмите здесь

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

    3. Lay a strip of Plastigage across each crankshaft journal.

      A012HRGC04
      *a Plastigage

    4. Install the crankshaft bearing cap.

      Click hereНажмите здесь

      Note:

      Do not turn the crankshaft.

    5. Remove the crankshaft bearing cap.

      Click hereНажмите здесь

    6. Measure the Plastigage at its widest point.

      A012MW8
      Standard oil clearance
      0.010 to 0.023 mm (0.000394 to 0.000906 in.)
      Maximum oil clearance
      0.07 mm (0.00276 in.)
      Note:

      Remove the Plastigage completely after the measurement.

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

      A012MO5C01
      *a Cylinder Block Sub-assembly Number *b Crank Journal Number
      *c Crankshaft Bearing Number - -
      Tip:

      • To select the correct crankshaft bearing size, calculate the crankshaft bearing number by adding together the numbers imprinted on the cylinder block sub-assembly and crank journal.

      • Example:

        Imprinted number on the cylinder block sub-assembly is 3.

        Imprinted number on the crank journal is 4.

        3 + 4 = 7

        Select a crankshaft bearing number 3.

        Number

        Cylinder Block Main Journal Bore Diameter

        mm (in.)

        Crank Main Journal Diameter

        mm (in.)
        0

        50.000 to 50.002

        (1.96850 to 1.96858)

        45.999 to 46.000

        (1.81098 to 1.81102)
        1

        50.003 to 50.004

        (1.96862 to 1.96866)

        45.997 to 45.998

        (1.81090 to 1.81094)
        2

        50.005 to 50.006

        (1.96870 to 1.96874)

        45.995 to 45.996

        (1.81082 to 1.81086)
        3

        50.007 to 50.009

        (1.96878 to 1.96885)

        45.993 to 45.994

        (1.81074 to 1.81078)
        4

        50.010 to 50.011

        (1.96890 to 1.96893)

        45.991 to 45.992

        (1.81067 to 1.81071)
        5

        50.012 to 50.013

        (1.96897 to 1.96901)

        45.998 to 45.990

        (1.81094 to 1.81063)
        6

        50.014 to 50.016

        (1.96905 to 1.96913)

        		 -

        Cylinder Block Sub-assembly

        Number + Crank

        Journal Number

        		 Crankshaft Bearing Number

        Crankshaft Bearing Thickness

        mm (in.)

        Oil Clearance

        mm (in.)
        0 to 2 1

        1.992 to 1.995

        (0.07843 to 0.07854)

        0.010 to 0.023

        (0.000394 to 0.000906)
        3 to 5 2

        1.996 to 1.998

        (0.07858 to 0.07866)

        		 ↑
        6 to 8 3

        1.999 to 2.001

        (0.07870 to 0.07878)

        		 ↑
        9 to 11 4

        2.002 to 2.004

        (0.07882 to 0.07890)

        		 ↑