Inspection

INSPECTION

CRANKSHAFT JOURNAL OIL CLEARANCE [PLASTIGAGE METHOD]

1. Remove oil from the crankshaft journal and crankshaft bearing.

2. Install the crankshaft.





3. Cut the plastigage to the same length as the width of bearing and place it on journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.





6. Measure the width of the plastigage at its widest part by using a scale printed on the plastigage package.

Standard value
Number 1, 2, 4: 0.018 - 0.036 mm (0.0007 - 0.0014 inch)
Number 3: 0.024 - 0.042 mm (0.0009 - 0.0017 inch)
Limit: 0.1 mm (0.003 inch)

CYLINDER BLOCK





1. Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter.

Standard value: 0.05 mm (0.0020 inch)
Limit: 0.1 mm (0.003 inch)

3. If the distortion is excessive, correct within the allowable limit or replace.

Grinding limit: 0.2 mm (0.007 inch)
*Includes/combined with cylinder head grinding
Cylinder block height (when new): 284 mm (11.2 inches)

4. Check cylinder walls for scratches and seizure. If defects are evident, replace or bore to oversize and replace pistons and piston rings.





5. Using a cylinder gauge, measure the cylinder bore and cylindrically. If worn badly, correct the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in the illustration.

Standard value:
Cylinder inner diameter 87.0 mm (3.43 inches)
Cylindrically 0.01 mm (0.0003 inch) or less


BORING CYLINDER





1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder.

Piston size identification






NOTE:
Size mark is stamped on the piston top.

2. Measure the outside diameter (Over diameter) of the piston to be used. Measure it in thrust direction as shown.
3. Based on the measured piston Over diameter, calculate the boring finish dimension.
Boring finish dimension = Piston Over diameter + (clearance between piston Over diameter and cylinder) - 0.02 mm (0.0008 inch) (honing margin)

CAUTION:
To prevent distortion that may result from temperature rise during honing, bore cylinders, working from number 2 to number 4 to number 1 to number 3.

4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston Over diameter + clearance between piston Over diameter and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
NOTE:
When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.