PROCEDURE
It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.
- V-belt
- Timing belt
- Valve rocker assembly
- Camshaft
- Cylinder head
GENERAL TOOL
| TOOL NAME | REMARKS |
|---|---|
| Compression gauge | Used for measuring compression. |
| Tachometer (Secondary pick-up type) | Used for measuring idle speed. |
| Timing light | Used for measuring ignition timing. |
GENERAL TOOL CHART
CAUTION
- Wear work clothing, including a cap, protective goggles and protective shoes during operation.
- Remove contamination including dirt and corrosion before removal, installation or disassembly.
- Keep the disassembled parts in order and protect them from dust and dirt.
- Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
- Be careful not to burn yourself, because each part on the vehicle is hot after running.
- Be sure to tighten fasteners including bolts and nuts to the specified torque.
- Place shop jacks or rigid racks at the specified points.
- Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery.
- All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings.
- Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
- Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.
- All removed parts, if to be reused, should be reinstalled in the original positions and directions.
- Bolts, nuts and washers should be replaced with new ones as required.
- Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
- Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
- Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fenders, as required, for protection.
- Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
- Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.
After removing the engine from the body, secure it in the ST shown below.
ST1 32005105 ENGINE STAND ADAPTER RH
ST2 32005106 ENGINE STAND ADAPTER LH
ST3 32005156 ENGINE STAND
Scheme 192
In this section the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process.
Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.
FRONT SIDE BELT
Remove the V-belt covers.
Scheme 193
Loosen the lock bolt (A).
Loosen the slider bolt (B).
Remove the front side belt (C).
Scheme 194
REAR SIDE BELT
Loosen the lock nut (A).
Loosen the slider bolt (B).
Scheme 195
Remove the rear side belt.
Remove the belt tensioner.
Scheme 196
Install a V belt (C), and tighten the slider bolt so as to obtain the specified belt tension.
Tighten the lock bolt (A).
Tighten the slider bolt (B).
Tightening torque
Lock bolt (A)
25 Nm (2.5 kgf-m, 18.1 ft -lb)
Scheme 197
Install the belt tensioner.
Install a V belt, and tighten the slider bolt (B) so as to obtain the specified belt tension.
Tighten the lock nut (A).
Tightening torque
Lock nut (A)
23 Nm (2.3 kgf-m, 17.0 ft -lb)
Scheme 198
TIMING BELT
Remove the V-belts.
Remove the crank pulley.
Remove the timing belt cover.
Remove the timing belt guide. (MT model)
Scheme 199
If the alignment mark or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below.
To turn crankshaft, use the ST: Align the mark (a) of sprocket to the cylinder block notch (b), and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted.
ST 32005170 CRANKSHAFT SOCKET
Scheme 200
Scheme 201
Using white paint, put alignment marks or arrow marks on the timing belts in relation to the crank sprocket and cam sprockets.
Scheme 202
Specified data
Z1: Length of 46.8 teeth
Z2: Length of 43.7 teeth
Scheme 203
Remove the belt idler (No. 2).
Remove the belt idler No. 2.
Scheme 204
Remove the timing belt.
Scheme 205
Prepare for installation of automatic belt tension adjuster assembly.
Installation of timing belt
Turn the cam sprocket No. 2 using ST1, and turn the cam sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions.
ST1 32005019 CAM SPROCKET WRENCH
ST2 32005125 CAM SPROCKET WRENCH
Scheme 206
While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, position the timing belt properly.
Scheme 207
Install the belt idler No. 2.
Tightening torque
39 Nm (4.0 kgf-m, 28.9 ft -lb)
Install the belt idler (No. 2).
Tightening torque
39 Nm (4.0 kgf-m, 28.9 ft -lb)
Scheme 208
After ensuring the marks on timing belt and cam sprockets are aligned, remove the stopper pin from belt tension adjuster.
Scheme 209
Install the timing belt guide. (MT model)
Temporarily tighten the timing belt guide mounting bolts.
Scheme 210
Check and adjust the clearance between timing belt and timing belt guide by using thickness gauge.
Clearance
1.0+/-0.5 mm (0.039+/-0.020 in)
Scheme 211
Tighten the timing belt guide mounting bolts.
Tightening torque
10 Nm (1.0 kgf-m, 7.2 ft-lb)
Scheme 212
Install the timing belt cover.
Install the crank pulley.
Install the V-belts.
Check the timing belt teeth for breaks, cracks and wear. If any fault is found, replace the belt.
Check the condition of the backside of belt. If cracks are found, replace the belt.
| IMPORTANT | Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Do not bend the timing belt sharply. |
In radial diameter h
60 mm (2.36 in) or more
Scheme 213
AUTOMATIC BELT TENSION ADJUSTER
Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly.
Note. Slight traces of oil at rod's oil seal does not indicate a problem.
Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness.
If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures
Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this operation two to three times.
With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check the adjuster rod stiffness.
If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one.
| IMPORTANT | Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press the adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder. |
Measure the amount of rod protrusion beyond the body. If it is not within specifications, replace with a new one.
Amount of rod protrusion H
5.7+/-0.5 mm (0.224+/-0.020 in)
Scheme 214
BELT TENSION PULLEY
Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly if faulty.
Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
Check the belt tension pulley for grease leakage.
BELT IDLER
Check the belt idler for smooth rotation. Replace if noise or excessive play occurs.
Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
Check the belt idler for grease leakage.
VALVE ROCKER ARM AND ROCKER SHAFT
Measure the inner diameter of valve rocker arm and outer diameter of valve rocker shaft, and determine the difference (oil clearance) between the two values.
Clearance between arm and shaft
Standard
0.020 - 0.054 mm (0.0008 - 0.0021 in)
Scheme 215
Scheme 216
If the oil clearance exceeds the standard value, replace the valve rocker arm or shaft, whichever shows greater amount of wear.
Rocker arm inside diameter
22.020 - 22.041 mm (0.8669 - 0.8678 in)
Rocker shaft diameter
21.987 - 22.000 mm (0.8656 - 0.8661 in)
If the cam or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker arm.
Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker arm.
CAMSHAFT
Measure the bend, and repair or replace if necessary.
Service limit
0.025 mm (0.00098 in)
Scheme 217
Check the journal for damage and wear. Replace if faulty.
Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal, and determine the difference (oil clearance) between the two values. If the oil clearance exceeds standard value, replace the camshaft or cylinder head as necessary.
| Unit: mm (in) | ||
|---|---|---|
| Clearance at journal | Standard | 0.055 - 0.090 (0.0022 - 0.0035) |
| Camshaft journal O.D. | 31.928 - 31.945 (1.2570 - 1.2577) | |
| Journal hole I.D. | 32.000 - 32.018 (1.2598 - 1.2605) | |
CAMSHAFT JOURNAL CHART
Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the limit, replace it.
Cam height: H
| Parts | Unit: mm (in) | |
|---|---|---|
| Intake | Standard | 39.485 - 39.585 (1.5545 - 1.5585) |
| Exhaust | Standard | 39.720 - 39.820 (1.5491 - 1.5530) |
CAM HEIGHT CHART
Cam base circle diameter A
Intake: 34.00 mm (1.3386 in)
Exhaust: 34.00 mm (1.3386 in)
Scheme 218
CAMSHAFT SUPPORT
Measure the side clearance of camshaft with setting the dial gauge at end of camshaft. If side clearance exceeds the limit, replace the camshaft support.
Standard
0.030 - 0.090 mm (0.0012 - 0.0035 in)
VALVE SPRING
Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table.
To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top of spring using a try square.
| Free length mm (in) | 54.30 (2.1378) | |
|---|---|---|
| Tension/spring height N (kgf, lb)/mm (in) | Set | 214 - 246 (22 - 25, 48 - 55)/45.0 (1.772) |
| Lift | 526 - 582 (54 - 59, 119 - 130)/34.7 (1.366) | |
| Squareness | 2.5°, 2.4 mm (0.094 in) or less | |
FREE LENGTH CHART
Scheme 219
INTAKE AND EXHAUST VALVE OIL SEAL
In the following case, pinch and remove the oil seal from valve using pliers, and then replace it with a new one.
- When the lip is damaged.
- When the spring is out of the specified position.
- When readjusting the surfaces of intake valve and valve sheet.
- When replacing the intake valve guide.
Place the cylinder head on ST1.
Using ST2, press-fit the oil seal.
| IMPORTANT | Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer or strike in. Differentiate between the intake valve oil seal and exhaust valve oil seal by noting their difference in color. |
ST1 32005098 CYLINDER HEAD TABLE
ST2 32005116 VALVE OIL SEAL GUIDE
Color of rubber part
Intake [Black]
Exhaust [Brown]
Scheme 220
CYLINDER HEAD
Make sure that no crack or other damage do not exist. In addition to visual inspection, inspect important areas by means of red lead check.
Also make sure the gasket installing surface shows no trace of gas and water leaks.
Place the cylinder head on the ST.
ST 32005098 CYLINDER HEAD TABLE
Measure the warping of the cylinder head surface that mates with crankcase using a straight edge and thickness gauge.
If the warping exceeds the limit, regrind the surface with a surface grinder.
Warping limit
0.03 mm (0.0012 in)
Grinding limit
0.1 mm (0.004 in)
Standard height of cylinder head
97.5 mm (3.839 in)
Note. Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.
Scheme 221
- Straight edge
- Thickness gauge
VALVE SEAT
Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.
Valve seat width W
Standard
Intake (A) 0.8 - 1.4 mm (0.03 - 0.055 in)
Exhaust (B) 1.2 - 1.8 mm (0.047 - 0.071 in)
Scheme 222
Scheme 223
VALVE GUIDE
Check the clearance between valve guide and stem. The clearance can be checked by measuring respectively the outer diameter of valve stem and inner diameter of valve guide with a micrometer.
Clearance between the valve guide and valve stem
Standard
Intake 0.035 - 0.062 mm (0.0014 - 0.0024 in)
Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in)
Scheme 224
Scheme 225
- A Valve guide
If the clearance between valve guide and stem exceeds the standard value, replace the valve guide or valve itself whichever shows greater amount of wear. See the following procedure for VALVE GUIDE REPLACEMENT .
Valve guide inner diameter
6.000 - 6.012 mm (0.2362 - 0.2367 in)
Valve stem outer diameters
Intake
5.950 - 5.965 mm (0.2343 - 0.2348 in)
Exhaust
5.945 - 5.960 mm (0.2341 - 0.2346 in)
Place the cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1.
Insert ST2 into the valve guide and press it down to remove the valve guide.
ST1 32005098 CYLINDER HEAD TABLE
ST2 32005148 VALVE GUIDE REMOVER
Scheme 226
Turn the cylinder head upside down and place the ST as shown in the figure.
Intake side
ST 32005150 VALVE GUIDE ADJUSTER
Exhaust side
ST 32005151 VALVE GUIDE ADJUSTER
Scheme 227
- Valve guide
Before installing a new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head.
Put a new valve guide, coated with sufficient oil, in cylinder, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2.
ST1 32005148 VALVE GUIDE REMOVER
Intake side
ST2 32005150 VALVE GUIDE ADJUSTER
Exhaust side
ST2 32005151 VALVE GUIDE ADJUSTER
Scheme 228
Check the valve guide protrusion.
Valve guide protrusion L
Intake
20.0 - 21.0 mm (0.787 - 0.827 in)
Exhaust
16.5 - 17.5 mm (0.650 - 0.689 in)
Scheme 229
- Valve guide
Ream the inside of valve guide using ST. Put the reamer in valve guide, and rotate the reamer slowly clockwise while pushing it lightly. Bring the reamer back while rotating it clockwise. After reaming, clean the valve guide to remove chips.
| IMPORTANT | Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer. |
ST 32005149 VALVE GUIDE REAMER
Scheme 230
Recheck the contact condition between valve and valve seat after replacing the valve guide.
INTAKE AND EXHAUST VALVE
Inspect the flange and stem of valve, and replace if damaged, worn or deformed, or if "H" exceed the standard value.
H
Intake
Standard: 0.8 - 1.2 mm (0.03 - 0.047 in)
Exhaust
Standard: 1.0 - 1.4 mm (0.039 - 0.055 in)
Valve overall length
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
Scheme 231
Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping.
CYLINDER BLOCK
Visually check for cracks and damage. Especially, inspect the important parts by means of red lead check.
Check the oil passages for clogging.
Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary.
Warping limit
0.025 mm (0.00098 in)
Grinding limit
0.1 mm (0.004 in)
Standard height of cylinder block
201.0 mm (7.91 in)
CYLINDER AND PISTON
The cylinder bore size is stamped on the cylinder block's front upper surface.
Note. Measurement should be performed at a temperature of 20°C (68°F). Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston.
Standard diameter
A: 99.505 - 99.515 mm (3.9175 - 3.9179 in)
B: 99.495 - 99.505 mm (3.9171 - 3.9175 in)
Scheme 232
- Main journal size mark
- Cylinder block (RH) -(LH) combination mark
- #1 cylinder bore size mark
- #2 cylinder bore size mark
- #3 cylinder bore size mark
- #4 cylinder bore size mark
How to measure the inner diameter of each cylinder
Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge.
Note. Measurement should be performed at a temperature of 20° C (68 °F).
Taper
Standard
0.015 mm (0.0006 in)
Out-of-roundness
Standard
0.010 mm (0.0004 in)
Scheme 233
- Piston pin direction
- Thrust direction H1 10 mm (0.39 in) H2 45 mm (1.77 in) H3 80 mm (3.15 in) H4 115 mm (4.53 in)
When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
How to measure the outer diameter of each piston
Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction)
Note. Measurement should be performed at a temperature of 20° C (68 °F).
Piston grade point H
37.0 mm (1.457 in)
Standard
A: 99.505 - 99.515 mm (3.9175 - 3.9179 in)
B: 99.495 - 99.505 mm (3.9171 - 3.9175 in)
0.25 mm (0.0098 in) oversize
99.745 - 99.765 mm (3.9270 - 3.9278 in)
0.50 mm (0.0197 in) oversize
99.995 - 100.015 mm (3.9368 - 3.9376 in)
Scheme 234
Calculate the clearance between cylinder and piston.
Note. Measurement should be performed at a temperature of 20° C (68 °F).
Cylinder to piston clearance at 20°C (68°F)
Standard
0.010 - 0.010 mm (- 0.00039 - 0.00039 in)
Boring and honing
If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the standard value or if there is any damage on the cylinder wall, rebore it to use an oversize piston.
| IMPORTANT | When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only. Nor use an oversize piston for one cylinder only. |
If the cylinder inner diameter exceeds limit after boring and honing, replace the cylinder block.
Limit of cylinder inner diameter
100.015 mm (3.9376 in)
Note. Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention when measuring the cylinder diameter.
Limit of cylinder boring
0.5 mm (0.020 in)
PISTON AND PISTON PIN
Check the pistons and piston pins for damage, cracks and wear, and the piston ring grooves for wear and damage. Replace if defective.
Measure the piston-to-cylinder clearance at each cylinder. If any of the clearances is not within the standard value, replace the piston. Or bore the cylinder to use an oversize piston.
Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68 °F). Replace if defective.
Clearance between piston hole and piston pin
Standard
0.004 - 0.008 mm (0.0002 - 0.0003 in)
Scheme 235
Scheme 236
Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
Scheme 237
Check the piston pin snap ring for distortion, cracks and wear.
PISTON RING
If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of the same size as the piston.
| IMPORTANT | Mark is displayed on the end of top and second rings. When installing the rings to the piston, face these marks upward. Oil ring consists of the upper rail, expander and lower rail. Be careful about the direction of rail when installing the oil ring to piston. |
Scheme 238
- Upper rail
- Expander
- Lower rail
Clean the piston ring groove and piston ring.
Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
| Standard mm (in) | ||
|---|---|---|
| Piston ring gap | Top ring | 0.20 - 0.35 (0.0079 - 0.0138) |
| Second ring | 0.37 - 0.52 (0.0144 - 0.020) | |
| Oil ring rail | 0.20 - 0.50 (0.0079 - 0.0197) | |
PISTON RING GAP CHART
Scheme 239
Measure the clearance between piston ring and piston ring groove with a thickness gauge.
| Standard mm (in) | ||
|---|---|---|
| Clearance between piston ring and piston ring groove | Top ring | 0.040 - 0.080 (0.0016 - 0.0031) |
| Second ring | 0.030 - 0.070 (0.0012 - 0.0028) | |
PISTON RING GAP CHART
Scheme 240
CONNECTING ROD
Replace the connecting rod, if the large or small end thrust surface is damaged.
Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in length
0.10 mm (0.0039 in)
Scheme 241
- Thickness gauge
- Connecting rod
Install the connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). If side clearance exceeds the limit, replace the connecting rod.
Connecting rod side clearance
Standard
0.070 - 0.330 mm (0.0028 - 0.0130 in)
Scheme 242
Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within the specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the TABLE below.)
Connecting rod oil clearance
Standard
0.016 - 0.044 mm (0.00063 - 0.0017 in)
| Unit: mm (in) | ||
|---|---|---|
| Bearings | Bearing size (Thickness at center) | Outer diameter of crank pin |
| Standard | 1.492 - 1.501 (0.0587 - 0.0591) | 51.984 - 52.000 (2.0466 - 2.0472) |
| 0.03 (0.0012) undersize | 1.510 - 1.513 (0.0594 - 0.0596) | 51.954 - 51.970 (2.0454 - 2.0461) |
| 0.05 (0.0020) undersize | 1.520 - 1.523 (0.0598 - 0.0600) | 51.934 - 51.950 (2.0446 - 2.0453) |
| 0.25 (0.0098) undersize | 1.620 - 1.623 (0.0638 - 0.0639) | 51.734 - 51.750 (2.0368 - 2.0374) |
CONNECTING ROD OIL CLEARANCE CHART
Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end.
Clearance between piston pin and bushing
Standard
0 - 0.022 mm (0 - 0.0009 in)
Scheme 243
Scheme 244
Replacement procedure is as follows.
Remove the bushing from connecting rod with ST and press.
Press the bushing with ST after applying oil on the periphery of bushing.
ST 32005122 CONNECTING ROD BUSHING REMOVER AND INSTALLER
Scheme 245
Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing.
After completion of reaming, clean the bushing to remove chips.
CRANKSHAFT AND CRANKSHAFT BEARING
Clean the crankshaft completely, and check it for cracks using red lead. Replace if faulty.
Measure the bend of crankshaft. If it exceeds the limit, repair or replace it.
Note. If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then measure the crankshaft bend using a dial gauge.
Crankshaft bend limit
0.035 mm (0.0014 in)
Scheme 246
Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used.
Crank pin
Out-of-roundness
0.003 mm (0.0001 in)
Cylindrically
0.004 mm (0.0002 in)
Grinding limit
To 51.750 mm (2.0374 in) dia.
Crank journal
Out-of-roundness
0.005 mm (0.0002 in)
Cylindrically
0.006 mm (0.0002 in)
Grinding limit
To 59.750 mm (2.3524 in) dia.
Scheme 247
| Unit: mm (in) | ||||
|---|---|---|---|---|
| Crank journal outer diameter | Crank pin outer diameter | |||
| #1, #3 | #2, #4, #5 | |||
| Standard | Journal O.D. | 59.992 - 60.008 (2.3619 - 2.3625) | 59.992 - 60.008 (2.3619 - 2.3625) | 51.984 - 52.000 (2.0466 - 2.0472) |
| Bearing size (Thickness at center) | 1.998 - 2.011 (0.0787 - 0.0792) | 2.000 - 2.013 (0.0787 - 0.0793) | 1.492 - 1.501 (0.0587 - 0.0591) | |
| 0.03 (0.0012) undersize | Journal O.D. | 59.962 - 59.978 (2.3607 - 2.3613) | 59.962 - 59.978 (2.3607 - 2.3613) | 51.954 - 51.970 (2.0454 - 2.0461) |
| Bearing size (Thickness at center) | 2.017 - 2.020 (0.0794 - 0.0795) | 2.019 - 2.022 (0.0795 - 0.0796) | 1.510 - 1.513 (0.0594 - 0.0596) | |
| 0.05 (0.0020) undersize | Journal O.D. | 59.942 - 59.958 (2.3599 - 2.3605) | 59.942 - 59.958 (2.3599 - 2.3605) | 51.934 - 51.950 (2.0446 - 2.0453) |
| Bearing size (Thickness at center) | 2.027 - 2.030 (0.0798 - 0.0799 | 2.029 - 2.032 (0.0799 - 0.0800) | 1.520 - 1.523 (0.0598 - 0.0600) | |
| 0.25 (0.0098) undersize | Journal O.D. | 59.742 - 59.758 (2.3520 - 2.3527) | 59.742 - 59.758 (2.3520 - 2.3527) | 51.734 - 51.750 (2.0368 - 2.0374) |
| Bearing size (Thickness at center) | 2.127 - 2.130 (0.0837 - 0.0839) | 2.129 - 2.132 (0.0838 - 0.0839) | 1.620 - 1.623 (0.0638 - 0.0639) | |
CRANK JOURNAL OUTER DIAMETER CHART
Measure the side clearance of crankshaft at center bearing. If clearance exceeds the limit, replace the bearing.
Crankshaft side clearance
Standard
0.030 - 0.115 mm (0.0012 - 0.0045 in)
Scheme 248
Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary.
Crankshaft oil clearance
Standard
0.010 - 0.030 mm (0.0004 - 0.0012 in)