Inspection

Components





Canada Models-Block Heater

PISTON AND PISTON PIN CLEARANCE





1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp": 20.969 - 20.981 mm (0.8255 - 0.8260 inch)





2. Measure outer diameter of piston pin "Dp".
Standard diameter "Dp": 20.971 - 20.983 mm (0.8256 - 0.8261 inch)
3. Calculate the piston to pin clearance.
Piston to pin clearance : dp - Dp = 0 - (-0.004) mm [0 - (-0.0002) in]
If the piston to pin clearance exceeds the specified value, replace the piston with pin assembly.

PISTON RING SIDE CLEARANCE





Measure the piston ring side clearance using a feeler gauge as shown.
Side clearance
Top ring : 0.040 - 0.080 mm (0.0016 - 0.0031 inch)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 inch)
Oil ring : 0.015 - 0.185 mm (0.0006 - 0.0073 inch)
Side clearance limit (maximum)
Top ring : 0.11 mm (0.0043 inch)
2nd ring : 0.1 mm (0.004 inch)
Oil ring :-
If out of specification, replace piston and/or piston ring assembly.

PISTON RING END GAP





Measure the piston ring end gap using a feeler gauge as shown.
End gap
Top ring : 0.21 - 0.31 mm (0.0083 - 0.0122 inch)
2nd ring : 0.50 - 0.60 mm (0.0197 - 0.0236 inch)
Oil ring : 0.20 - 0.60 mm (0.0079 - 0.0236 inch)
End gap limit (maximum)
Top ring : 0.43 mm (0.0169 inch)
2nd ring : 0.69 mm (0.0272 inch)
Oil ring : 0.34 mm (0.0331 inch)
If the piston ring end gap is out of specification, replace the piston ring. If the end gap still exceeds the limit with a new ring, rebore the cylinder and use an oversized piston and piston rings.

CAUTION: When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION





Bend limit : 0.15 mm (0.0059 inch) per 100 mm (3.94 inch) length
Torsion limit : 0.30 mm (0.0118 inch) per 100 mm (3.94 inch) length





If it exceeds the limit, replace connecting rod assembly.

CYLINDER BLOCK DISTORTION AND WEAR





1. Clean upper face of cylinder block and measure the upper face distortion using a feeler gauge and a straight edge as shown.
Cylinder block distortion
Standard : less than 0.03 mm (0.0012 inch)
Limit :0.1 mm (0.004 inch)
2. If the cylinder block upper face distortion is out of specification, resurface the cylinder block upper face. The resurfacing limit is determined by cylinder head resurfacing.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "B".
Maximum resurfacing limit (A + B): 0.2 mm (0.008 inch)
Nominal cylinder block height at crankshaft center: 227.60 - 227.70 mm (8.9606 - 8.9645 inch)
3. If necessary, replace the cylinder block.

PISTON-TO-CYLINDER BORE CLEARANCE





1. Using a bore gauge, measure the cylinder bore for out-of-round, taper, standard inner diameter, and wear.
Out-of-round (difference between X and Y) standard : 0.015 mm (0.0006 inch)
Taper (difference between A and C) standard : 0.015 mm (0.0006 inch)





If the measurements exceed specifications, rebore all of the cylinder bores. Replace the cylinder block if necessary.











2. Check the cylinder bores for scratches and damage. If any are found, hone the cylinder bores. If necessary replace the cylinder block and use the chart to select the proper grade pistons.
^ If both the cylinder block and pistons are replaced with new ones, select a piston of the correct grade number according to the following table. These numbers are punched on the cylinder block and piston in either Arabic or Roman numerals.





3. Measure Piston skirt diameter as shown.
Measuring point "a" (distance from the top): 49.0 mm (1.929 inch)
4. Check that piston-to-cylinder bore clearance is within specification.
Piston-to-cylinder bore clearance "B"
No. 1, 2, and 6 (No. 5 VG33ER only) cylinders : 0.025 - 0.045 mm (0.0010 - 0.0018 inch)
No. 3 and 4 cylinders : 0.015 - 0.025 mm (0.0006 - 0.0010 inch)
No. 5 cylinder (VG33E only) : 0.030 - 0.040 mm (0.0012 - 0.0016 inch)
5. Determine the piston oversize according to the amount of cylinder bore wear.

NOTE: Oversize pistons are available for service.

6. The cylinder bore rebore size is calculated by adding the piston diameter "A" to the piston-to-cylinder bore clearance "B" when subtracting the honing allowance.
Cylinder bore rebore size calculation (D = A + B - C)
where,
D: cylinder bore rebore diameter
A: piston diameter as measured
B: piston-to-bore clearance
C: honing allowance of 0.02 mm (0.0008 inch)
7. Install the main bearing caps, and tighten the main bearing cap bolts to specification to prevent distortion of the cylinder bores when honing.
8. Hone the cylinder bores.

CAUTION:
^ When any cylinder bore needs honing, all of the other cylinders must also be honed.
^ Do not hone too much out of a cylinder bore at one time. Hone no more than 0.05 mm (0.0020 inch) increase in diameter at a time.

9. Hone the cylinders to obtain the specified piston-to-bore clearance.
10. Measure the finished cylinder bore for out-of-round and taper.
^ Measurements should be done after the cylinder bore cools down.

CRANKSHAFT





1. Check crankshaft main and pin journals for score, wear or cracks.
2. With a micrometer, measure the journals for taper and out-of- round.
Out-of-round (X - Y) : less than 0.005 mm (0.0002 inch)
Taper (A - B) : less than 0.005 mm (0.0002 inch)





3. Measure the crankshaft runout using a dial gauge as shown.
Runout (total indicator reading) : less than 0.10 mm (0 0039 inch)

BEARING CLEARANCE
Method A (using a bore gauge and micrometer)

NOTE: Either of the following two methods (A and B) may be used, however, method A gives more reliable results and is preferable over method B for measuring bearing clearance.

Main Bearing





1. Set main bearings in their proper positions on cylinder block and main bearing cap.
2. Install the main bearing caps on to the cylinder block, tighten the main bearing cap bolts to specification.





3. Measure inner diameter "A" at each main bearing.





4. Measure outer diameter "Dm" at each crankshaft main journal.
5. Calculate main bearing clearance.
No. 1 main bearing clearance (A- Dm)
Standard :0.030 - 0.048 mm (0.0012 - 0.0019 inch)
Limit : 0.060 mm (0.0024 inch)
No. 2, 3, 4 main bearing clearance (A- Dm)
Standard : 0.038 - 0.065 mm (0.0015- 0.0026 inch)
Limit : 0.080 mm (0.0031 inch)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.





a. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 inch)
b. Grind the crankshaft to specification, and use available service parts.





8. If the crankshaft is reused, measure the main bearing clearances and then select the thickness of the main bearings. If the crankshaft is replaced with a new one, it is necessary to select the thickness of the main bearings as follows:
1. The grade number of each cylinder block main journal is punched on the respective cylinder block main journal as shown. These grade numbers are punched in either Arabic or Roman numerals.





2. The grade number of each crankshaft main journal is punched on the crankshaft as shown. These grade numbers are punched in either Arabic or Roman numerals
3. Select the main bearing with a suitable thickness according to the following tables.





No.1 Main Bearing Grade Number (Identification Color)





Except No.1 Main Bearing Grade Number (Identification Color)

Connecting Rod Bearing (Big end)
1. Install the connecting rod bearings on to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten the bolts to the specified torque.





3. Measure the inner diameter "C" of each connecting rod bearing as shown.





4. Measure the outer diameter "Dp" of each crankshaft pin journal as shown.
5. Calculate the connecting rod bearing clearance.
Connecting rod bearing clearance (C - Dp)
Standard : 0.024 - 0.064 mm (0.0009 - 0.0025 inch)
Limit : 0.090 mm (0.0035 inch)
6. If the connecting rod bearing clearance exceeds the limit, replace the bearing.
7. If the clearance cannot be adjusted to within the standard for any bearing, then grind the crankshaft journals and use undersized bearings.

Method B (using Plastigage)





CAUTION:
^ Do not turn the crankshaft or the connecting rod while the Plastigage is being inserted.
^ When the bearing clearance exceeds the specified limit, check that the correct size bearing has been installed. Then if any excessive bearing clearance exists, use a thicker main bearing or an undersized bearing so that the specified bearing clearance is obtained.

CONNECTING ROD BUSHING CLEARANCE (SMALL END)





1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance (C - Dp)
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 inch)
Limit : 0.023 mm (0.0009 inch)
If it exceeds the specified limit, replace the connecting rod assembly or connecting rod bushing and/or piston set with pin.

REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)





1. Drive in small end bushing until it is flush with end surface of rod.

CAUTION: Align the oil holes as shown for proper lubrication.

2. After driving in small end bushing, ream the bushing so that clearance between connecting rod bushing and piston pin is the specified value.
Clearance between connecting rod bushing and piston pin : 0.005 - 0.017 mm (0.0002 - 0.0007 inch)

FLYWHEEL/DRIVE PLATE RUNOUT





Measure the runout using a dial gauge as shown. The runout is measured with a dial gauge reading from a full rotation of the flywheel (M/T only) or driveplate (A/T only).
Runout (total indicator reading)
Flywheel (M/T only) : less than 0.15 mm (0.0059 inch)
Drive plate (A/T only) : less than 0.15 mm (0.0059 inch)

CAUTION:
^ Be careful not to damage the ring gear teeth.
^ Check the drive plate for deformation or cracks.
^ Do not allow any magnetic materials to contact the ring gear teeth.
^ Do not surface flywheel or drive plate. Replace as necessary