Engine Mechanical (H4DOTC): Other Subaru Forester SG рестайлинг

CAUTION

1. Wear work clothing, including a cap, protective goggles and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Be careful not to burn your hands, because each part on the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery.
9. All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings.
10. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
11. Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.
12. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
13. Bolts, nuts and washers should be replaced with new ones as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making re-checks.
15. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
16. Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection.
17. Prior to starting work, prepare the following

Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.

1. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

GENERAL TOOL

PROCEDURE

It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this information are based on the condition that the engine is removed from the vehicle.

1. V-belt
2. Timing belt
3. Camshaft
4. Cylinder head

FRONT SIDE BELT

1. Remove the collector cover.
2. Loosen the lock bolt (A).
3. Loosen the slider bolt (B).
4. Remove the front side belt (C).

Scheme 436

Scheme 437

1. Loosen the lock nut (A).
2. Loosen the slider bolt (B). see scheme 62: Identifying Rear Slider Bolt And Lock Nut
3. Remove the A/C belt.
4. Remove the belt tensioner.

Scheme 438

1. Install the belt (C), and tighten the slider bolt (B) so as to obtain the specified belt tension. INSPECTION V-BELT.>
2. Tighten the lock bolt (A).
3. Tighten the slider bolt (B). Tightening torque: Lock bolt through bolt: 25 N.m (2.5 kgf-m, 18.1 ft-lb) Slider bolt 8 N.m (0.8 kgf-m, 5.5 ft-lb) see scheme 64: Identifying Front Side Belt, Lock And Slider Bolt

REAR SIDE BELT

1. Install a belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. INSPECTION V-BELT.>
2. Tighten the lock nut (A). Tightening torque: Lock nut (A); 22.6 N.m (2.3 kgf-m, 16.6 ft-lb) see scheme 65: Identifying Rear Slider Bolt And Lock Nut

Scheme 439

Scheme 440

1. Replace the belts, if crack, fraying or wear is found.
2. Check the drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position. Belt tension (with belt tension gauge): (A) When installing new parts: 640 - 780 N (65 - 80 kgf, 144 - 175 lb) At inspection: 490 - 640 N (50 - 65 kgf, 110- 144 lb) (B)* When installing new parts: 740 - 880 N (76 - 89 kgf, 167 - 197 lb) At inspection 350 - 450 N (36 - 46 kgf, 78 - 101 lb) *: Model with air conditioner see scheme 66: Checking Belt Tension (With Belt Tension Gauge) Belt tension (without belt tension gauge): (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 in) At inspection 9-11 mm (0.354 - 0.433 in) (B)* When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 in) At inspection 9.0 - 10.0 mm (0.354 - 0.394 in) *: Model with air conditioner see scheme 67: Checking Belt Tension (Without Belt Tension Gauge)

Scheme 441

1. Remove the V-belts. REMOVAL V-BELT.>
2. Remove the crank pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH see scheme 68: Locking Crankshaft Using Crank Pulley Wrench ST 499977100
3. Remove the crank pulley.

TIMING BELT

1. Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the belt.
2. Check the condition of the backside of belt. If cracks are found, replace the belt.

Bending diameter: h

60 mm (2.36 in) or more

Scheme 442

Scheme 443

1. Visually check the oil seals for leaks, and rod ends for uneven wear and 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.
2. 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 the adjuster rod stiffness.
3. 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 cylinder. Repeat this operation two to three times. With the adjuster rod extended all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it to inspect the stiffness of the adjuster rod. If the adjuster rod is not stiff and compresses, replace the automatic belt tension adjuster assembly with a new one. CAUTION: 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-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder.
4. Measure the amount of rod protrusion beyond the body. If it is not within specifications, replace with new one. Amount of rod protrusion: H 5.2 - 6.2 mm (0.204 - 0.244 in) see scheme 108: Identifying Amount Of Rod Protrusion

BELT TENSION PULLEY

1. Check the mating surfaces of timing belt and contact point of adjuster rod for uneven wear or scratches. Replace the automatic belt tension adjuster assembly if faulty.
2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3. Check the belt tension pulley for grease leakage.

BELT IDLER

1. Check the belt idler for smooth rotation. Replace if noise or excessive play occurs.
2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check the belt idler for grease leakage.

Scheme 444

Scheme 445

1. Remove the V-belts. REMOVAL V-BELT.>
2. Remove the crank pulley. REMOVAL CRANK PULLEY.>
3. Remove the timing belt cover. REMOVAL TIMING BELT COVER.>
4. Remove the timing belt. REMOVAL TIMING BELT.>
5. Fasten the cam sprocket and remove from the cam shaft using ST. ST 499207400 CAM SPROCKET WRENCH see scheme 109: Locating Cam Sprocket Wrench ST 499207400 ST 499977500 CAM SPROCKET WRENCH see scheme 110: Locating Cam Sprocket Wrench ST 499977500

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

Intake

Standard

0.6 - 1.4 mm (0.024 - 0.055 in)

Service limit

1.7 mm (0.067 in)

Exhaust

Standard

1.2 - 1.8 mm (0.047-0.071 in)

Service limit

2.2 mm (0.087 in)

Scheme 446

Scheme 447

Scheme 448

Scheme 449

1. Check the clearance between valve guide and stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. Clearance between the valve guide and valve stem: Standard: Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in) Service limit: 0.15 mm (0.0059 in)
2. If the clearance between valve guide and valve stem exceeds the limit, 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 5.955 - 5.970 mm (0.2344 - 0.2350 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 fit the holes in ST1. Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER see scheme 146: Inserting Valve Guide Remover ST2 499767200 Into Valve Guide Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA020 VALVE GUIDE ADJUSTER see scheme 147: Identifying Valve Guide Adjuster ST 18251AA020 On Cylinder Head Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. Put a new valve guide, coated with sufficient oil, in the cylinder head, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 18251AA020 VALVE GUIDE ADJUSTER see scheme 148: Inserting Valve Guide Remover ST1 499767200 Into Valve Guide Check the valve guide protrusion. Valve guide protrusion: L 15.8 - 16.2 mm (0.622 - 0.638 in) Insert the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. (Reaming Work) After reaming, clean the valve guide to remove chips. ST 499767400 VALVE GUIDE REAMER CAUTION: Apply engine oil to the ST when reaming. NOTE: If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. Recheck the contact condition between valve face and valve seat after replacing the valve guide.

Scheme 450

1. Inspect the flange and stem of valve, and replace if damaged, worn, or deformed. If "H" is less than the specified limit, replace with a new valve. H: Intake (A) Standard: 1.0 - 1.4 mm (0.039 - 0.055 in) Service limit: 0.8 mm (0.031 in) Exhaust (B) Standard: 1.3 - 1.7 mm (0.057 - 0.067 in) Service limit: 0.8 mm (0.031 in) see scheme 149: Identifying Intake And Exhaust Valve Flange And Stem
2. Put a small amount of grinding compound on the seat surface, and lap the valve and valve seat. NOTE: Replace with a new valve oil seal after lapping. It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake (A) 104.4 mm (4.110 in) Exhaust (B) 104.65 mm (4.120 in)

Scheme 451

1. Check the valve springs for damage, free length, and spring constant. Replace the valve spring if it is not within standard values presented in the table.
2. 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. VALVE SPRING SPECIFICATIONS Valve spring Free length 47.32 mm (1.863 in) Tension/spring height Set 205 - 235 N (20.9 - 24.0 kgf, 46.1 - 52.8 lb) /36.0 mm (1.417 in) Lift 426 - 490 N (43.4 - 50.0 kgf, 95.8 - 110 lb) /26.50 mm (1.041 in) Squareness 2.5°, 2.1 mm (0.083 in) or less see scheme 150: Measuring Squareness Of Valve Spring

Scheme 452

1. For the following, replace the oil seal with a new one. See the procedure 2) and subsequent for replacement procedures. 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.
2. Place the cylinder head on ST1.
3. Press-fit the oil seal to the specified dimension indicated in the figure using ST2. ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE CAUTION: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer or strike in. Note that the intake valve oil seal and exhaust valve oil seal are differentiated by colors. Color of rubber part: Intake [Gray] Exhaust [Green] see scheme 151: Installing Oil Seal Using Valve Oil Seal Guide ST2 498857100

Scheme 453

Scheme 454

1. Check the valve lifter visually.
2. Measure the outer diameter of valve lifter. Outer diameter: 34.959 - 34.975 mm (1.3763 - 1.3770 in) see scheme 152: Identifying Valve Lifter Outer Diameter
3. Measure the inner diameter of valve lifter mating surface on cylinder head. Inner diameter: 34.994 - 35.016 mm (1.3777 - 1.3786 in) see scheme 153: Measuring Inner Diameter Of Valve Lifter NOTE: If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the limit, replace the cylinder head. Standard: 0.019 - 0.057 mm (0.0007 - 0.0022 in) Service limit: 0.100 mm (0.0039 in)

DISPOSAL

Scheme 455

1. If the valve is damaged, remove the valve and neutralize it by immersing it in water, and dispose of it in the same way that general steel materials are disposed of. The disposal method is described in the following. Wearing rubber gloves, remove the damaged valve from the cylinder head. Prepare a large receptacle (bucket or other container) in a well ventilated location, and fill the receptacle with water, (at least 10 liters) Immerse the damaged valve in the receptacle. CAUTION: A severe reaction may occur, so stand at least 2 - 3 m from the receptacle. Because the reaction will produce hydrogen gas, moreover, keep the receptacle away from sparks or flames. Once the reaction is completed (about 4 - 5 hours have elapsed), carefully remove the valve using large pincers so that the reaction liquid does not contact your skin, and dispose of it with other parts that are being disposed of. The reaction liquid is a strong alkaline solution, so it must be disposed of in accordance with local regulations. CAUTION: Make sure the reaction liquid does not contact your skin. If contact with skin occurs, immediately wash the affected area with large quantities of water. see scheme 154: Disposing Of Valve

CYLINDER BLOCK

1. Visually check for cracks and damage. Use liquid penetrant tester on the important sections to check for fissures.
2. Check the oil passages for clogging.
3. Inspect the crankcase 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)

Scheme 456

Scheme 457

Scheme 458

1. The cylinder bore size is stamped on the cylinder block 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) see scheme 197: Identifying Piston Grade Mark
2. 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) Service limit: 0.050 mm (0.0020 in) Out-of-roundness: Standard: 0.010 mm (0.0004 in) Service limit: 0.050 mm (0.0020 in) see scheme 198: Identifying Heights And Measuring Directions
3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. 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: 38.2 mm (1.50 in) Piston outer diameter: Standard: A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) Standard: 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) see scheme 199: Measuring Outer Diameter Of Piston
5. 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 (-0.0004 - 0.0004 in) Service limit: 0.030 mm (0.0012 in)
6. Boring and honing: If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replace to oversize pistons. Do not perform boring on one cylinder only. Nor replace an oversize piston for one cylinder only. If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, measure when it has cooled to room temperature. Limit of cylinder boring: 0.5 mm (0.020 in)

Scheme 459

Scheme 460

Scheme 461

1. Check the piston and piston pin for breaks, cracks or wear. Replace if faulty.
2. Check the piston ring groove for wear and damage. Replace if faulty.
3. Measure the piston-to-cylinder clearance at each cylinder. CRANKSHAFT AND PISTON INSPECTION, CYLINDER BLOCK.> If any of the clearances is not within specification, replace the piston or bore the cylinder to use an oversize piston.
4. Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if faulty. Standard clearance between piston pin and hole in piston: Standard: 0.004 - 0.008 mm (0.0002 - 0.0003 in) Service limit: 0.020 mm (0.0008 in) see scheme 200: Measuring Inner Diameter Of Piston Hole see scheme 201: Measuring Piston Pin Diameter
5. 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. see scheme 202: Identifying Snap Ring Installation Groove
6. Check the piston pin snap ring for distortion, cracks and wear.

Scheme 462

Scheme 463

Scheme 464

1. 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 piston. CAUTION: Marks are shown on the end of top and second rings. When installing the rings to piston, face this mark upward. Oil ring consists of the upper rail, expander and lower rail. When installing on piston, be careful of each rail's direction. see scheme 203: Identifying Ring Upper Rail, Expander And Lower Rail
2. Squarely place the piston ring and oil ring in cylinder using the piston, and measure the piston ring gap with a thickness gauge. PISTON RING GAPS Unit: mm (in) Standard Limit Piston ring gap Top ring 0.20 - 0.25 (0.0079 - 0.0098) 1.0(0.039) Second ring 0.37 - 0.52 (0.015 - 0.020) 1.0(0.039) Oil ring rail 0.20 - 0.50 (0.0079 - 0.0197) 1.5(0.059) see scheme 204: Measuring Piston Ring Gap Using Thickness Gauge
3. Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. CLEARANCE SPECIFICATIONS Unit: mm (in) Standard Limit Clearance between piston ring and piston ring groove Top ring 0.040 - 0.080 (0.0016 - 0.0031) 0.15 (0.0059) Second ring 0.030 - 0.070 (0.0012 - 0.0028) 0.15 (0.0059) see scheme 205: Measuring Clearance Between Piston Ring And Piston Ring Groove Using Thickness Gauge

Scheme 465

Scheme 466

Scheme 467

Scheme 468

1. Replace the connecting rod, if the large or small end thrust surface is damaged.
2. 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) see scheme 206: Checking Connecting Bend Or Twist Using Connecting Rod Aligner
3. Install the connecting rod fitted with bearing to the crankshaft and measure the side clearance (thrust clearance) using a thickness gauge. Replace the connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard: 0.070 - 0.330 mm (0.0028 - 0.0130 in) Service limit: 0.4 mm (0.016 in) see scheme 207: Measuring Connecting Rod Side Clearance
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or under-size as necessary. (See «CONNECTING ROD OIL CLEARANCE SPECIFICATION»(ref-274170-S24351588932007121400000) below.) Connecting rod oil clearance: Standard: 0.017 - 0.045 mm (0.0007 - 0.0018 in) Service limit: 0.05 mm (0.0020 in) CONNECTING ROD OIL CLEARANCE SPECIFICATION Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.490 - 1.502 (0.0587 - 0.0591) 51.984 - 52.000 (2.0466 - 2.0472) 0.03 (0.0012) undersize 1.504 - 1.512 (0.0592 - 0.0595) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) undersize 1.514 - 1.522 (0.0596 - 0.0599) 51.934 - 51.950 (2.0447 - 2.0453) 0.25 (0.0098) undersize 1.614 - 1.622 (0.0635 - 0.0639) 51.734 - 51.750 (2.0368 - 2.0374)
6. Inspect the bushing at connecting rod small end, and replace with a new one if worn or damaged.
7. Measure the piston pin clearance at connecting rod small end. Replace it with a new one if the limit has been exceeded. Clearance between piston pin and bushing: Standard: 0 - 0.022 mm (0 - 0.0009 in) Service limit: 0.030 mm (0.0012 in) see scheme 208: Measuring Piston Pin Clearance At Connecting Rod Small End see scheme 209: Measuring Piston Pin Diameter
8. The replacement procedure for the connecting rod small end bushing is as follows. Remove the bushing from connecting rod with ST and press. Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER & INSTALLER see scheme 210: Pressing Bushing With Connecting Rod Bushing Remover & Installer ST 499037100 Make two 3 mm (0.12 in) holes in bushing. Then ream the inside of the bushing. After completion of reaming, clean the bushing to remove chips.

Scheme 469

Scheme 470

Scheme 471

1. Clean the crankshaft completely, and check for cracks by means of red lead check etc., If faulty, replace with new a new crankshaft.
2. Measure the bend of crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, use only a #1 and #5 crankshaft bearing on cylinder block, and position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in) see scheme 211: Measuring Crankshaft Bend Using Dial Gauge
3. Inspect the crank journal and crank pin for wear. If they are not within the specification, replace the bearing with a suitable (undersize) one, and replace or grind to correct the 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) Cylindricality: 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) Cylindricality: 0.006 mm (0.0002 in) Grinding limit: To 59.750 mm (2.3524 in) dia. see scheme 212: Inspecting Crank Journal And Crank Pin Wear CRANK JOURNAL AND CRANK PIN OUTER DIAMETER 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) 1.490 - 1.502 (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) 1.504 - 1.512 (0.0592 - 0.0595) 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 (2.0447 - 2.0453) Bearing size (Thickness at center) 2.027 - 2.030 (0.0798 - 0.0799) 2.029 - 2.032 (0.0799 - 0.0800) 1.514 - 1.522 (0.0596 - 0.0599) 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) 1.614 - 1.622 (0.0635 - 0.0639)
4. Use a thickness gauge to measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace the bearing. Crankshaft thrust clearance: Standard: 0.030 - 0.115 mm (0.0012 - 0.0045 in) Service limit: 0.25 mm (0.0098 in) see scheme 213: Measuring Thrust Clearance Of Crankshaft At Center Bearing
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
6. Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value 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 - 0.0072 in) Service limit: 0.040 mm (0.0016 in)