Inspection

CYLINDER BLOCK INSPECTION

1. CLEAN CYLINDER BLOCK
A. Remove gasket material
Using a gasket scraper. remove all the gasket material from the top surface of the cylinder block.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.

2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.

3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

4. INSPECT CYLINDER BORE DIAMETER

HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.

Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter:
Mark "1" 86.000 - 88.010 mm (3.3858 - 3.3862 in.)
Mark "2" 86.010 - 86.020 mm (3.3862 - 3.3866 in.)
Mark "3" 86.020 - 86.030 mm (3.3866 - 3.3870 in.)
Maximum diameter: 86.23 mm (3.3949 in.)
If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
PISTON AND CONNECTING ROD DISASSEMBLY

1. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and oil ring by hand. HINT: Arrange the piston rings in correct order only.

3. DISCONNECT CONNECTING ROD FROM PISTON

(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 - 90°C (176 - 194°F).

(c) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin, Or, use SST press and press out the piston pin. SST 09221-25024 (09221-00020, 09221-00030, 09221-00060, 09221-00160, 09221-00170) and remove the connecting rod.

NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

PISTON AND CONNECTING ROD INSPECTION
1 CLEAN PISTON

(a) Using a gasket scraper, remove the carbon from the piston top.

(b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

A. Inspect piston oil clearance
HINT: There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top.

(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 25.4 mm (1,000 in.) from the piston head.
Piston diameter:
Mark "1" 85.945 - 85.955 mm (3.3836 - 3.3840 in.)
Mark "2" 85.955 - 85.965 mm (3.3840 - 3.3844 in.)
Mark "3" 85.965 - 85.975 mm (3.3844 - 3.3848 in.)

(b) Measure the cylinder bore diameter in the thrust directions.
(c) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.045 - 0.065 mm (0.0018 - 0.0032 in.)
Maximum oil clearance: 0.085 mm (0.0033 in.)
If the oil clearance is greater than maximum, replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block.

HINT (Use new cylinder block): Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.

B. Inspect piston ring groove clearance
Using a feeler gauge. measure the clearance between new piston ring and the wall of the piston ring groove. Ring groove clearance:
No.1 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
If the clearance is greater than maximum, replace the piston.
C. Inspect piston ring end gap

(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 11O mm (4.33 in.) from the top of the cylinder block.

(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No.1 0.270 - 0.500 mm (0.0106 - 0.197 in.)
No.2 0.270 - 0.510 mm (0.0106 - 0.0201 in.)
Oil (Side rail) 0.200 - 0.550 mm (0.0079 - 0.0217 in.)
Maximum end gap:
No.1: 1.10 mm (0.0433 in.)
No.2: 1.11 mm (0.0437 in.)
Oil (Side rail): 1.15 mm (0.0453 in.)
If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

D. Inspect piston pin fit
At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb.
3. INSPECT CONNECTING ROD

A. Inspect connecting rod alignment
Using a rod aligner and thickness gauge, check the connecting rod alignment.
Check for bend.
Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod assembly.

Check for twist
Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod assembly.

CRANKSHAFT INSPECTION AND REPAIR
1. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT
(a) Place the crankshaft on V-blocks.

(b) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crankshaft.
2. INSPECT MAIN JOURNALS AND CRANK PINS

(a) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter:
STD 54.988 - 55.003 mm (2.1649 - 2.1655 in.)
U/S 0.25
54.745 - 54.745 - 54.755 mm (2.1553 - 2.1557 in.)
Crank pin diameter:
STD 47.985 - 48.000 mm (1.8892-1.8898 in.)
U/S 0.25
47.745 - 47.985 mm (1.8892 - 1.8898 in)
If the diameter is not as specified, check the oil clearance. (See steps 3 and 6 in cylinder block disassembly in Engine Mechanical) If necessary, grind or replace the crankshaft.
(b) Check each main journal and crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace the crankshaft.
3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure in step 2). Install new main journal and/or crankshaft pin undersized bearings.
CRANKSHAFT OIL SEALS REPLACEMENT

HINT: There are 2 methods (A and B) to replace the oil seal which are as follows:

1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If oil pump is removed from cylinder block:

(a) Using SST and hammer, tap out the oil seal.

(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09226-10010
(c) Apply MP grease to the oil seal lip.
B. If oil pump is Installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.

(b) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.

(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09226-10010
2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder block:

(a) Using a screwdriver and hammer, tap out the oil seal.

(b) Using SST and a hammer. tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-63010)
(c) Apply MP grease to the oil seal lip.
B. If rear oil seal retainer is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.

(b) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft. Tap the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.

(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST (09223-63010)
PISTON AND CONNECTING ROD ASSEMBLY
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring one side of the piston pin hole.
(b) Gradually heat the piston to 80 - 90°C (176 - 194° F).
(c) Coat the piston pin with engine oil.

(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
(e) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Code mark: No.1 1T or 1N
Code mark: No.2 2T or 2N

(c) Position the piston rings so that the ring ends are as shown.

NOTICE: Do not align the piston ring ends.

3 INSTALL BEARINGS

(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod cap.

CAUTION: Install the bearing with the hole in the rod