Engine Block Inspection
INSPECTIONCONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.
^ If out-of-tolerance, install a new connecting rod.
^ If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
2) Remove the 2 connecting rod cap nuts.
3) Remove the connecting rod cap and lower bearing.
4) Clean the crankshaft pin journal and bearing.
5) Place a plastigage across the crankshaft pin journal.
6) Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque: 31.4 - 34.3 Nm (3.2 - 3.5 kgf.m, 23.1 - 25.3 ft. lbs.)
NOTE: Do not turn the crankshaft
7) Remove the 2 nuts, connecting rod cap and lower bearing.
8) Measure the plastigage at its widest point.
9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.
Recheck the oil clearance.
CAUTION: Do not file, shim, of scrape the bearings or the caps to adjust clearance.
10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
Recheck the oil clearance.
NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
CONNECTING ROD BEARING MARK LOCATION:
IDENTIFICATION OF CONNECTING ROD:
CRANKSHAFT PIN JOURNAL MARK LOCATION:
IDENTIFICATION OF CRANKSHAFT PIN JOURNAL:
CONNECTING ROD BEARING MARK LOCATION:
IDENTIFICATION OF CONNECTING ROD BEARING:
11) Select the bearing by using selection table.
CONNECTING ROD BEARING SELECTION TABLE:
3. Check the connecting rods.
1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod: 0.05 mm / 100 mm (0.0020 inch / 3.94 inch) or less
Allowable twist of connecting rod: 0.1 mm / 100 mm (0.0039 inch / 3.94 inch) or less
4. Check the crankshaft bearing oil clearance.
1) To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.
2) Clean each main journal and lower bearing with a clean shop towel.
3) Place one strip of plastigage across each main journal.
4) Reinstall the lower bearings and caps, then tighten the bolts.
Tightening torque: 53.9 - 58.8 Nm (5.5 - 6.0 kgf.m, 39.8 - 43.4 ft. lbs.)
NOTE: Do not turn the crankshaft.
5) Remove the cap and lower bearing again, and measure the widest part of the plastigage.
6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.
Recheck the oil clearance.
CAUTION: Do not file, shim, or scrape the bearings or the cap to adjust clearance.
7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
Recheck the oil clearance.
NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Cylinder block crankshaft journal bore mark location
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings.
IDENTIFICATION OF CYLINDER BLOCK CRANKSHAFT JOURNAL BORE:
CRANKSHAFT MAIN JOURNAL MARK LOCATION:
IDENTIFICATION OF CRANKSHAFT MAIN JOURNAL:
CRANKSHAFT MAIN BEARING MARK LOCATION:
IDENTIFICATION OF CRANKSHAFT MAIN BEARING:
8) Select the bearing by using selection table.
CRANKSHAFT MAIN BEARING SELECTION TABLE:
5. Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
If the end play is greater than maximum, replace the center bearing.
6. Inspect the crankshaft main journals and pin journals. Using a micrometer, measure the diameter of each main journal and pin journal.
CYLINDER BLOCK
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
4. Inspect the cylinder bore.
Visually check the cylinder for vertical scratches.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
6. Check the cylinder bore size code on the cylinder block bottom face.
IDENTIFICATION OF CYLINDER BORE SIZE:
7. Check the piston size mark (A) on the piston top face.
DISCRIMINATION OF PISTON OUTER DIAMETER:
8. Select the piston related to cylinder bore class.
Piston-to-cylinder clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D (Outer Diameter), calculate the new bore size.
New bore size = piston 0.D + 0.02 to 0.04 mm (0.0008 to 0.0016 inch) (clearance between piston and cylinder) - 0.01 mm (0.0004 inch) (honing margin.)
4. Bore each of the cylinders to the calculated size.
CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
NOTE: When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.
(1.6 CVVT: Don't use over size)
PISTON AND PISTON RINGS
1. Clean the piston.
1) Using a gasket scraper, remove the carbon from the piston top.
2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
3) Using solvent and a brush, thoroughly clean the piston.
NOTE: Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 39.15 mm (1.5413 inch) from top land of the piston.
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is over the service limit, the cylinder block must be rebored.
PISTON PINS
1. Measure the outer diameter of piston pin
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance: 0.011 - 0.018 mm (0.0004 - 0.0007 inch)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference: -0.033 - -0.016 mm (-0.0013 - -0.0006 inch)
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 49.0 kPa (0.5 kg/cm2, 7.1 psi) vacuum is applied through the oil hole, the switch is operating properly.