Inspection

INSPECTION

CRANKSHAFT JOURNAL OIL CLEARANCE [PLASTIGAGE METHOD]

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

2. Install the crankshaft.





3. Cut plastigage to the same length as the width of the bearing and place it on the journal in parallel with its axis.





4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
Tightening torque: 74± 4Nm (54± 3 ft-lb)
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastigage at its widest section by using a scale printed on the plastigage bag.
Standard value:

0.012 - 0.030 mm (0.0005 - 0.0012 inch)[ Number 1, 4]
0.018 - 0.036 mm (0.0007 - 0.0014 inch)[ Number 2, 3]
Limit: 0.1 mm (0.003 inch)


CRANKSHAFT REAR OIL SEAL

1. Check the oil seal lip for wear and damage.

2. Check the rubber for deterioration or hardening.

3. Check the oil seal case for cracks and damage.

CYLINDER BLOCK

1. Visually check for scratches, rust, and corrosion. Use 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 (0.002 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 (0.008 inch)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):

227.9 - 228.1 mm (8.972 - 8.980 inches)






4. Check the cylinder walls for scratches and seizure. If defects are evident, correct
(bored to an oversize) or replace.
5. Using a cylinder gauge, measure the cylinder bore and cylindricality. If worn badly, correct by boring the cylinders to an oversize and replace pistons and piston rings. Measure at the points shown in the illustration.
Standard value:

Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)


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 of the piston to be used. Measure it in the thrust direction as shown.
3. Based on the measured piston Outside Diameter (OD), calculate the boring finish dimension.
Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin)
4.
CAUTION:
To prevent distortion that may result from temperature rise during honing, bore cylinders in the order of number 2, number 4, number 6, number 1, number 3 and number 5.

5. Bore all cylinders to the calculated boring finish dimension.
6. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
Standard value:

Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
7. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:

0.03 - 0.05 mm (0.0012 - 0.0020 inch)
NOTE:
When boring cylinders, finish all six cylinders to the same oversize. Do not bore only one cylinder to an oversize.