Engine Mechanical: Other Suzuki SX4 I

Engine Construction

The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double over head camshaft) valve mechanism arranged for "V" type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing chains, and no push rods are provided in the valve train system.

Scheme 121

Scheme 122

IMT (Intake manifold tuning) system varies effective length of intake pipe by opening and closing IMT valve in order to improve air volumetric efficiency.

As intake valve in cylinder head is opened and closed repeatedly, intake air pulsation always exists. If intake valve is opened when air pressure is momentarily maximum, intake air volumetric efficiency is increased. This momentary maximum air pressure depends on effective intake pipe length.

When IMT valve is fully open [A]

The effective intake pipe length is shorter. Engine torque between middle and high engine speed ranges is improved, whilst it drops between low and middle engine speed ranges.

When IMT valve is totally closed [B]

The effective intake pipe length is longer. Engine torque between middle and high engine speed ranges drops, while it is improved between low and middle ranges.

IMT system utilizes this characteristic of engine. IMT valve is closed between low and middle engine speed ranges, and opened between middle and high engine speed ranges.

In this way, engine torque is improved in whole engine speed ranges.

Compression Check

Check compression pressure on all 4 cylinders as follows

Scheme 123

Scheme 124

1. Warm up engine.
2. Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift lever in "Neutral" (shift selector lever to "P" range for A/T model), and set parking brake and block drive wheels.
3. Remove ignition coils and all spark plugs, referring to «REMOVAL»(ref-268902-S29441137252007102700000) .
4. Disconnect fuel injector wire harness at the connector.
5. Install special tool (Compression gauge) into spark plug hole. Special Tool 09915-64512 09915-64530 09915-67010
6. Disengage clutch (to lighten starting load on engine) for M/T vehicle, and depress accelerator pedal all the way to make throttle fully open.
7. Crank engine with fully charged battery, and read the highest pressure on compression gauge. NOTE: For measuring compression pressure, crank engine at least 250 r/min by using fully charged battery. If measured compression pressure is lower than limit value, check installation condition of special tool. Compression pressure Standard: 1400 kPa (14.0 kgf/cm 2 , 199.0 psi) Limit: 1100 kPa (11.0 kgf/cm 2 , 158.0 psi) Max. difference between any two cylinders: 100 kPa (1.0 kgf/cm 2 , 14.2 psi)
8. Carry out Steps 5 through 7 on each cylinder to obtain 4 readings.
9. After checking, install spark plugs and ignition coils, referring to «INSTALLATION»(ref-268902-S02014904302007102700000) .
10. Connect injector wire harness at connector.
11. Install air cleaner assembly, referring to «INSTALLATION»(ref-268922-S40663716002007102700000) .

Engine Vacuum Check

The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The vacuum checking procedure is as follows

Scheme 125

Scheme 126

1. Warm up engine to normal operating temperature. NOTE: After warming up engine, be sure to place transaxle gear shift lever in "Neutral" (Shift selector lever to "P" range for A/T model), and set parking brake and block drive wheels.
2. Stop engine and turn off the all electric switches.
3. Remove air cleaner assembly, referring to «REMOVAL»(ref-268922-S32478541502007102700000) .
4. Remove hose (1) from PCV valve (2).
5. Connect special tool (Vacuum gauge) to PCV hose (1). Special Tool (A): 09915-67311
6. Blind PCV valve (2) using tape (3) or the like.
7. Install air cleaner assembly, referring to «INSTALLATION»(ref-268922-S40663716002007102700000) .
8. Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 - 73 kPa (45 - 55 cmHg, 17.7 - 21.6 in.Hg) at specified idle speed
9. After checking, remove air cleaner assembly.
10. Disconnect special tool (Vacuum gauge) from PCV valve.
11. Detach blind cap from PCV valve.
12. Connect PCV hose to PCV valve.
13. Install air cleaner assembly.

Scheme 127

Scheme 128

1. Remove negative (-) cable at battery.
2. Remove cylinder head cover, referring to «REMOVAL»(ref-268922-S19545546592007102700000).
3. Using 17 mm wrench, turn crankshaft pulley (1) clockwise until index (2) of cylinder block and index (3) of crankshaft pulley (1) are aligned.
4. Check whether cam position (1) of No.1 cylinder is at the specified position [A] (Scheme 128) If cam position is [B], locate cam position to [A] by turning crankshaft one rotation.
5. Check valve lashes with thickness gauge (1) according to the following procedure. Check valve lashes of cylinder No.1. Turn crankshaft pulley by 180° clockwise. Check valve lashes of cylinder No.3. In the same manner as b and c, check valve lashes of cylinder No.4 then cylinder No.2.

If valve lash is out of specification, record valve lash and adjust it to specification by replacing shim.

Valve clearance specification

VALVE CLEARANCE SPECIFICATION

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

1. Close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside.
2. Lift down the valve by turning crankshaft to 360°.
3. Hold tappet at that position using special tool as follows. Remove its housing bolts. Check housing No. and select special tool corresponding to housing No., referring to «SPECIAL TOOL SELECTION TABLE»(ref-268922-S36775521732007102700000) . SPECIAL TOOL SELECTION TABLE No. on camshaft housing Embossed mark on special tool I2, I3, I4, I5 IN E2, E3, E4, E5 EX Hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt (1) tighten housing bolts by hand. Special Tool (A): 09916-66510
4. Turn camshaft by approximately 90° clockwise and remove shim (3). WARNING: Never put in the hand between camshaft and tappet.
5. Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and «SHIM THICKNESS SPECIFICATION TABLE»(ref-268922-S34235612822007102700000) . Shim thickness specification Intake side: A = B + C - 0.20 mm (0.008 in.) Exhaust side: A = B + C - 0.30 mm (0.012 in.) Thickness of new shim Thickness of removed shim Measured valve clearance For example of intake side: When thickness of removed shim is 2.40 mm (0.094 in.), and measured valve clearance is 0.45 mm (0.018 in.). A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) - 0.20 mm (0.008 in.) = 2.65 mm (0.104 in.) Calculated thickness of new shim = 2.65 mm (0.104 in.)
6. Select new shim No. (1) with a thickness as close as possible to calculated value. Available new shims No . SHIM THICKNESS SPECIFICATION TABLE Thickness mm (in.) Shim No. Thickness mm (in.) Shim No. 2.175 (0.0856) 218 2.600 (0.1024) 260 2.200 (0.0866) 220 2.625 (0.1033) 263 2.225 (0.0876) 223 2.650 (0.1043) 265 2.250 (0.0886) 225 2.675 (0.1053) 268 2.275 (0.0896) 228 2.700 (0.1063) 270 2.300 (0.0906) 230 2.725 (0.1073) 273 2.325 (0.0915) 233 2.750 (0.1083) 275 2.350 (0.0925) 235 2.775 (0.1093) 278 2.375 (0.0935) 238 2.800 (0.1102) 280 2.400 (0.0945) 240 2.825 (0.1112) 283 2.425 (0.0955) 243 2.850 (0.1122) 285 2.450 (0.0965) 245 2.875 (0.1132) 288 2.475 (0.0974) 248 2.900 (0.1142) 290 2.500 (0.0984) 250 2.925 (0.1152) 293 2.525 (0.0994) 253 2.950 (0.1161) 295 2.550 (0.1004) 255 2.975 (0.1171) 298 2.575 (0.1014) 258 3.000 (0.1181) 300
7. Install new shim facing shim No. side with tappet.
8. Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4 ) and remove special tool. Special Tool (A): 09916-66510
9. Install camshaft housing (1) and tighten bolts to specified torque. Tightening torque Camshaft housing bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
10. Turn crankshaft pulley more than 4 rotations.
11. Check valve clearance again.
12. After checking and adjusting all valves, install cylinder head cover, referring to «INSTALLATION»(ref-268922-S19355082212007102700000) .

Scheme 138

Cleaning

Blow off dust by compressed air from air outlet side of element.

Scheme 139

Scheme 140

Electric Throttle Body Cleaning

Clean electric throttle body assembly referring to "Throttle Valve Operation Check" under ELECTRIC THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION .

Clean

Clean sealing surface on timing chain cover, crank case, cylinder block and cylinder head.

Remove oil, old sealant, and dust from sealing surface.

Timing Chain Guide No.2

Check shoe (2) for wear or damage.

Scheme 141

Camshaft Sprocket

Check teeth of sprocket for wear or damage.

Scheme 142

Timing Chain

Check timing chain for wear or damage.

Scheme 143

Tensioner Adjuster No.2

Check shoe (1) for wear or damage and latch functions properly.

Scheme 144

Scheme 145

Timing Chain Guide No.1

Check shoe for wear or damage.

Scheme 146

Timing Chain Tensioner

Check shoe (1) for wear or damage.

Scheme 147

Crankshaft Timing Sprocket

Check teeth of sprocket for wear or damage.

Scheme 148

Idler Sprocket

Check teeth and bush (1) of sprocket for wear or damage.

Scheme 149

1st Timing Chain

Check timing chain for wear or damage.

Scheme 150

Timing Chain Tensioner Adjuster No.1

Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.

Scheme 151

Scheme 152

Cam Wear

Using a micrometer, measure cam height. If measured height is below its limit, replace camshaft.

Cam height "a"

CAM HEIGHT SPECIFICATION

Scheme 153

Camshaft Runout

Set camshaft between two "V" blocks, and measure its runout by using a dial gauge.

If measured runout exceeds the specified limit, replace camshaft.

Runout limit

0.03 mm (0.0012 in.)

Scheme 154

Camshaft Journal Wear

Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.

If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housings.

Scheme 155

Check clearance by using gauging plastic. Checking procedure is as follows.

Scheme 156

1. Clean housings and camshaft journals.
2. Make sure that all tappets with shims are removed and install camshafts to cylinder head.
3. Place a piece of gauging plastic to full width of journal of camshaft (parallel to camshaft).
4. Install camshaft housing.
5. Tighten camshaft housing bolts in such order as indicated in (Scheme 157) a little at a time till they are tightened to specified torque. NOTE: Do not rotate camshaft while gauging plastic is installed. Tightening torque Camshaft housing bolt a: Tighten 11 N.m (1.1 kgf-m, 8.0 lb-ft) by the specified procedure
6. Remove housing, and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. Journal clearance JOURNAL CLEARANCE SPECIFICATION Standard Limit 0.020 - 0.074 mm (0.0008 - 0.0029 in.) 0.12 mm (0.0047 in.)

Scheme 157

If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater.

Camshaft journal

CAMSHAFT JOURNAL SPECIFICATION

Scheme 158

Wear of Tappet and Shim

Check tappet and shim for pitting, scratches, or damage.

If any malcondition is found, replace.

Scheme 159

Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.

Cylinder head bore and tappet outside diameter

CYLINDER HEAD BORE AND TAPPET OUTSIDE DIAMETER

Scheme 160

Oil Relief Valve

Check oil relief valve for clogging and ball for being stuck.

Scheme 161

Scheme 162

Valve stem-to-guide clearance

Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance.

Be sure to take reading at more than one place along the length of each stem and guide.

If clearance exceeds limit, replace valve and valve guide.

Valve stem and valve guide specification

VALVE STEM AND VALVE GUIDE SPECIFICATION

Scheme 163

Valve stem end deflection

If bore gauge is not available, check end deflection of valve stem with a dial gauge instead.

Move stem end in directions (1) and (2) to measure end deflection.

If deflection exceeds its limit, replace valve stem and valve guide.

Valve stem end deflection limit

In: 0.14 mm (0.005 in.)

Ex: 0.18 mm (0.007 in.)

Scheme 164

Scheme 165

1. Remove all carbon from valves.
2. Inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it.
3. Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve.

Valve head thickness

Measure thickness "a" of valve head. If measured thickness exceeds limit, replace valve.

Valve head thickness "a"

Intake

Standard: 1.25 - 1.55 mm (0.049 - 0.061 in.)

Limit: 0.9 mm (0.035 in.)

Exhaust

Standard: 1.45 - 1.75 mm (0.057 - 0.069 in.)

Limit: 1.1 mm (0.04 in.)

Scheme 166

Valve head radial runout

Check each valve for radial runout with a dial gauge and "V" block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve.

Valve head radial runout

Limit: 0.08 mm (0.003 in.)

Scheme 167

Seating contact width

Create contact pattern on each valve in the usual manner, i.e., by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used.

Pattern produced on seating face of valve must be a continuous ring without any break, and the width of pattern must be within specified range.

Standard seating width "a" revealed by contact pattern on valve face

Intake and Exhaust: 1.0 - 1.4 mm (0.0389 - 0.0551 in.)

Scheme 168

Valve seat repair

A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.

Scheme 169

1. Exhaust valve seat: Use valve seat cutters (1) to make two cuts see scheme 132 Two cutters must be used: the first for making 15° angle, and the second for making 45° angle. The second cut must be made to produce desired seat width. Seat width for exhaust valve seat "a": 1.0 - 1.4 mm (0.0389 - 0.0551 in.)
2. Intake valve seat: Use valve seat cutters (1) to make three cuts see scheme 132 Three cutters must be used: the 1st for making 25° angle, the 2nd for making 60° angle, and 3rd for making 45° angle. The 3rd cut (45°) must be made to produce desired seat width. Seat width for intake valve seat "b": 1.0 - 1.4 mm (0.0389 - 0.0551 in.)
3. Valve lapping: Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the second with fine-size compound, each time using valve lapper according to usual lapping method.

Valve Spring Free Length and Preload

Referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.

Valve spring free length

Standard: 51.13 mm (2.013 in.)

Limit: 50.13 mm (1.974 in.)

Valve spring preload

Standard: 209 - 241 N (20.9 - 24.1 kgf) for 37.60 mm (46.1 - 53.1 lb/1.480 in.)

Limit: 208 N (20.8 kgf) for 37.60 mm (45.9 lb/1.480 in.)

Scheme 170

Spring Squareness

Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit must be replaced.

Valve spring squareness

Limit: 2.2 mm (0.087 in.)

Scheme 171

Scheme 172

Cylinder

1. Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston.
2. Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions (Scheme 174) If any of following conditions is noted, rebore cylinder.

Scheme 173

1. Cylinder bore diameter exceeds limit.
2. Difference of measurements at two positions exceeds taper limit.
3. Difference between thrust and axial measurements exceeds out-of-round limit. Cylinder bore diameter Standard: 84.000 - 84.020 mm (3.3070 - 3.3078 in.) Limit: 84.050 mm (3.3090 in.) Taper and out-of-round Limit: 0.10 mm (0.004 in.) NOTE: If any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance.

Scheme 174

Scheme 175

1. Inspect piston for faults, cracks or other damages. Damaged or faulty piston should be replaced.
2. Piston diameter: As indicated in (Scheme 175), piston diameter should be measured at a position 26.5 mm (1.04 in.) ("a") from piston skirt end in the direction perpendicular to piston pin. Piston diameter PISTON DIAMETER Standard 83.9700 - 83.9900 mm (3.3059 - 3.3067 in.) Oversize: 0.50 mm (0.0196 in.) 84.4700 - 84.4900 mm (3.3256 - 3.3264 in.)
3. Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance 0.02 - 0.04 mm (0.0008 - 0.0015 in.) NOTE: Cylinder bore diameters used here are measured in thrust direction at two positions.
4. Ring groove clearance: Before checking, piston grooves must be clean, dry and free of carbon. Fit new piston ring (1) into piston groove, and measure clearance between ring and ring land by using thickness gauge (2). If clearance is out of specification, replace piston. Ring groove clearance RING GROOVE CLEARANCE SPECIFICATION Item Standard Limit Top ring 0.03 - 0.07 mm (0.0120 - 0.0027 in.) 0.12 mm (0.0047 in.) 2nd ring 0.02 - 0.06 mm (0.0008 - 0.0023 in.) 0.1 mm (0.0039 in.) Oil ring 0.06 - 0.15 mm (0.0024 - 0.0059 in.)

Scheme 176

1. Check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly worn or damaged, replace pin, connecting rod or piston.
2. Piston pin clearance: Check piston pin clearance in small end. Replace connecting rod if its small end is badly worn or damaged or if measured clearance exceeds limit. Piston pin clearance in small end Standard: 0.003 - 0.014 mm (0.0001 - 0.0005 in.) Piston pin clearance in piston Standard: 0.006 - 0.017 mm (0.00024 - 0.00067 in.) Small-end bore [A] 21.003 - 21.011 mm (0.8269 - 0.8272 in.) Piston pin diameter [B] 20.997 - 21.000 mm (0.8267 - 0.8268 in.) Piston bore 21.006 - 21.014 mm (0.8270 - 0.8273 in.)

Piston rings

To measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge (1). If measured gap is out of specification, replace ring.

Note. Clean carbon and any other dirt from top of cylinder bore before inserting piston ring.

Piston ring end gap

PISTON RING END GAP SPECIFICATION

Piston rings end gap

"a": 120 mm (4.72 in.)

Scheme 177

Scheme 178

Scheme 179

1. Big-end side clearance: Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod. Big-end side clearance BIG-END SIDE CLEARANCE SPECIFICATION Standard Limit 0.25 - 0.40 mm (0.0099 - 0.0150 in.) 0.45 mm (0.0177 in.)
2. Connecting rod alignment: Mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it. Limit on bow 0.05 mm (0.0020 in.) Limit on twist 0.10 mm (0.0039 in.)

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

1. Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of round or taper is out of limit, replace crankshaft or regrind crank pin. Connecting rod bearing and crank pin CONNECTING ROD BEARING AND CRANK PIN SPECIFICATION Item Standard Crank pin diameter 49.982 - 50.000 mm (1.9768 - 1.9685 in.) Out-of-round "A"-"B" Taper "a"-"b" Out-of-round and taper limits 0.01 mm (0.0004 in.)
2. Connecting rod bearing general information: Inspect bearing shells for signs of fusion, pitting, burn or flaking and observe contact pattern. Bearing shells found in defective condition must be replaced. Two kinds of connecting rod bearings are available; standard size bearing and 0.25 mm (0.0098 in.) undersize bearing. For identification of undersize bearing, it is painted red (1) at the position as indicated in (Scheme 182), undersize bearing thickness is 1.605 - 1.615 mm (0.0632 - 0.0635 in.) at the center of it.
3. Connecting rod bearing clearance: Before checking bearing clearance, clean bearing and crank pin. Install bearing in connecting rod and bearing cap. Place a piece of gauging plastic (1) to full width of crank pin as contacted by bearing (parallel to crankshaft), avoiding oil hole. Install connecting rod bearing cap (1) as follows. Point arrow mark (2) on cap to crankshaft pulley side. Apply engine oil to connecting rod bolts (3). Tighten all connecting rod bolts to 15 N.m (1.5 kgf-m, 11.0 lb-ft). Retighten them by turning through 45°. Repeat step d once again. Tightening torque Connecting rod bolt a: Tighten 15 N.m (1.5 kgf-m, 11.0 lb-ft), 45° and 45° by the specified procedure NOTE: Do not turn crankshaft with gauging plastic installed. Remove connecting rod bearing cap, and using a scale (2) on gauging plastic envelope, measure gauging plastic (1) width at the widest point (clearance). If clearance exceeds its limit, select connecting rod bearing by referring to «PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND CLEANING»(ref-268922-S38657426232007102700000) below mentioned item. After selecting new bearing, recheck clearance. Bearing clearance BEARING CLEARANCE SPECIFICATION Standard Limit 0.045 - 0.063 mm (0.0018 - 0.0025 in.) 0.08 mm (0.0031 in.) If clearance can not be brought to within its limit even by using a new standard size bearing, replace crankshaft or regrind crankpin to undersize as follows. Install 0.25 mm undersize bearing to connecting rod big end. Measure bore diameter of connecting rod big end. Regrind crankpin to the following finished diameter. Finished crankpin diameter = Measured big end bore diameter (including undersize bearing) - 0.054 mm (0.0021 in.) Confirm that bearing clearance is within the standard value. NOTE: After checking the connecting rod bearing clearance, make sure to check for "Connecting rod bolt" under «PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND CLEANING»(ref-268922-S38657426232007102700000).
4. Selection of connecting rod bearings: NOTE: If bearing is in malcondition or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. When replacing crankshaft or connecting rod and its bearing due to any reason, select new standard bearings to be installed by referring to numbers stamped on connecting rod and its cap and/or alphabets stamped on crank web of No. 3 cylinder. Check stamped numbers on connecting rod and its cap (Scheme 186) Three kinds of numbers ("1", "2" and "3") represent the following connecting rod big end inside diameters. For example, stamped number "1" indicates that corresponding connecting rod big-end inside diameter is 53.0000 - 53.0060 mm (2.0867 - 2.0868 in.). Connecting rod big-end inside diameter CONNECTING ROD BIG-END INSIDE DIAMETER Stamped numbers Connecting rod big-end inside diameter 1 53.0000 - 53.0060 mm (2.0867 - 2.0868 in.) 2 53.0061 - 53.0120 mm (2.0869 - 2.0870 in.) 3 53.0121 - 53.0180 mm (2.0871 - 2.0873 in.) Next, check crank pin diameter. On crank web of No. 3 cylinder, four alphabets are stamped (Scheme 187) Three kinds of alphabet ("A", "B" and "C") represent the following crank pin diameter respectively. For example, stamped "A" indicates that corresponding crank pin diameter is 49.9940 - 50.0000 mm (1.9683 - 1.9685 in.). Crank pin diameter CRANK PIN DIAMETER Stamped alphabet Crank pin diameter (without bearing) A 49.9940 - 50.0000 mm (1.9683 - 1.9685 in.) B 49.9880 - 49.9939 mm (1.9681 - 1.9682 in.) C 49.9820 - 49.9879 mm (1.9677 - 1.9680 in.) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in (Scheme 188). Each color indicated the following thickness at the center of bearing. Standard size of connecting rod bearing thickness STANDARD SIZE OF CONNECTING ROD BEARING THICKNESS SPECIFICATION Color painted Bearing thickness Green 1.482 - 1.485 mm (0.05835 - 0.05846 in.) Black 1.485 - 1.488 mm (0.05847 - 0.05858 in.) Colorless 1.488 - 1.491 mm (0.05859 - 0.05870 in.) Yellow 1.491 - 1.494 mm (0.05871 - 0.05881 in.) Blue 1.494 - 1.497 mm (0.05882 - 0.05893 in.) From number stamped on connecting rod and its cap and alphabet stamped on crank web No. 3 cylinder, determine new standard bearing to be installed to connecting rod big-end inside, by referring to «SPECIFICATIONS OF STANDARD CONNECTING ROD BEARING SIZE TABLE»(ref-268922-S40603732372007102700000). For example, if number stamped on connecting rod and its cap is "1" and alphabet stamped on crank web No. 3 cylinder is "B", install a new standard bearing painted in "Black" to its connecting rod big-end inside. Specifications of new standard connecting rod bearing size SPECIFICATIONS OF STANDARD CONNECTING ROD BEARING SIZE TABLE Number stamped on connecting rod and its cap (Connecting rod big end inside diameter) 1 2 3 Alphabet stamped on crank web of No. 3 cylinder (Crank pin diameter) A Green Black Colorless B Black Colorless Yellow C Colorless Yellow Blue Check bearing clearance with newly selected standard bearing by referring to «CRANK PIN AND CONNECTING ROD BEARINGS»(ref-268922-S10152393602007102700000). If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
5. Connecting rod bolt Measure each thread diameter of connecting rod bolts (1) at "A" on 28.5 mm (1.12 in.) from bolt mounting surface and "B" on 42.0 mm (1.65 in.) from bolt mounting surface by using a micrometer (2). Calculate difference in diameters ("A"-"B"). If it exceeds limit, replace connecting rod. Connecting rod bolt measurement points "a": 28.5 mm (1.12 in.) "b": 42.0 mm (1.65 in.) Connecting rod bolt diameter difference limit ("A"-"B"): 0.1 mm (0.004 in.)

Clean carbon from piston head and ring grooves, using a suitable tool.

Scheme 189

1. Disconnect negative (-) cable at battery.
2. Drain engine coolant.
3. Remove exhaust manifold cover.
4. Remove engine block heater (1).

Crankshaft runout

Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft.

Limit on runout

0.06 mm (0.0023 in.)

Scheme 190

Crankshaft thrust play

Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and lower crankcase installed. Tighten crankcase bolts by referring to MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION .

Use a dial gauge to read displacement in axial (thrust) direction of crankshaft.

If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard thrust play.

Crankshaft Thrust Play

Standard: 0.10 - 0.35 mm (0.0039 - 0.0137 in.)

Limit: 0.42 mm (0.0149 in.)

Scheme 191

Thickness of crankshaft thrust bearing

THICKNESS OF CRANKSHAFT THRUST BEARING SPECIFICATION

Scheme 192

Out-of-round and taper (uneven wear) of journals

An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This difference, if any, is determined by taking micrometer readings. If any one of journals is badly damaged or if amount of uneven wear in the sense exceeds its limit, regrind or replace crankshaft.

Limit on out-of-round and taper

0.01 mm (0.0004 in.)

Out-of-round

"A"-"B"

Taper

"a"-"b"

Scheme 193

Main bearing clearance

Check clearance by using gauging plastic according to the following procedure.

1. Remove lower crankcase.
2. Clean bearings and main journals.
3. Place a piece of gauging plastic (1) to full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
4. Install lower crankcase to cylinder block by referring to «INSTALLATION»(ref-268922-S23665160432007102700000) . NOTE: Do not rotate crankshaft while gauging plastic is installed.
5. Remove lower crankcase and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use of 0.25 mm undersize bearing. After selecting new bearing, recheck clearance. Main bearing clearance Standard: 0.020 - 0.038 mm (0.00079 - 0.00149 in.) Limit: 0.063 mm (0.0024 in.)

Scheme 194

Selection of main bearings STANDARD BEARING

1. Bearing is in malcondition.
2. Bearing clearance is out of specification.
3. Crankshaft or cylinder block is replaced.

Scheme 195

Scheme 196

Scheme 197

1. First check journal diameter. (Scheme 197), crank web No.2 has stamped numbers. Six kinds of numbers ("4" through "9") represent the following journal diameters. Journal diameter JOURNAL DIAMETER AND STAMPED NUMBERS Stamped numbers Journal diameter 4 58.0030 - 58.0060 mm (2.28358 - 2.28369 in.) 5 58.0000 - 58.0029 mm (2.28346 - 2.28357 in.) 6 57.9970 - 57.9999 mm (2.28334 - 2.28345 in.) 7 57.9940 - 57.9969 mm (2.28323 - 2.28333 in.) 8 57.9910 - 57.9939 mm (2.28311 - 2.28322 in.) 9 57.9880 - 57.9909 mm (2.28299 - 2.28310 in.) Stamped numbers on crank web No.2 (3) represent journal diameters marked with an arrow in (Scheme 197) respectively. For example, stamped number "5" indicates that corresponding journal diameter is 58.0000 - 58.0029 mm (2.28346 - 2.28357 in.).
2. Next, check journal bore diameter. On lower crankcase five alphabets are stamped (Scheme 198) Three kinds of alphabets ("A", "B" and "C") represent the following journal bore diameters. Journal bore diameter JOURNAL BORE DIAMETER AND STAMPED ALPHABET Stamped alphabet Journal bore diameter A 61.9940 - 62.0000 mm (2.44070 - 2.44094 in.) B 62.0001 - 62.0060 mm (2.44095 - 2.44117 in.) C 62.0061 - 62.0120 mm (2.44118 - 2.44141 in.) Stamped alphabets on lower crankcase represent journal diameter marked with an arrow in figure respectively. For example, stamped alphabet "A" at No.2 journal indicates that (journal) bore diameter of No.2 journal is 61.9940 - 62.0000 mm (2.44070 - 2.44094 in.).
3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted (1) in the following colors at the position as indicated in (Scheme 199). Each color indicates the following thickness at the center of bearing. Standard size main bearing thickness STANDARD SIZE MAIN BEARING THICKNESS SPECIFICATION Color painted Bearing thickness Green 1.9910 - 1.9940 mm (0.07839 - 0.07850 in.) Black 1.9940 - 1.9970 mm (0.07851 - 0.07862 in.) Colorless (no painted) 1.9970 - 2.0000 mm (0.07863 - 0.07874 in.) Yellow 2.0000 - 2.0030 mm (0.07874 - 0.07885 in.) Blue 2.0030 - 2.0060 mm (0.07886 - 0.07897 in.)
4. From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal by referring to «MAIN BEARING CROSS-REFERENCE TABLE»(ref-268922-S18734412612007102700000). For example, if number stamped on crank web No.2 is "5" and alphabet stamped on lower crankcase is "A", install new standard bearings painted in "Green" to cylinder block side journal and "Black" to lower crankcase side journal. NOTE: The meaning of "Upper" and "Lower" described in «MAIN BEARING CROSS-REFERENCE TABLE»(ref-268922-S18734412612007102700000). Upper: It is instruction of main bearing installed in cylinder block side journal. Lower: It is instruction of main bearing installed in lower crankcase side journal. Main bearing cross-reference table (new standard bearing) MAIN BEARING CROSS-REFERENCE TABLE Standard number on crank web No.2 4 5 6 7 8 9 Standard alphabet on lower crankcase A Green Upper: Green Lower: Black Black Upper: Black Lower: Colorless Colorless Upper: Colorless Lower: Yellow B Black Upper: Black Lower: Colorless Colorless Upper: Colorless Lower: Yellow Yellow Upper: Yellow Lower: Blue C Colorless Upper: Colorless Lower: Yellow Yellow Upper: Yellow Lower: Blue Blue Blue
5. Check main bearing clearance with newly selected standard bearing referring to «MAIN BEARING CLEARANCE»(ref-268922-S38185712732007102700000). If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

Scheme 198

Scheme 199

1. 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted (1) in the following colors at such position as indicated in (Scheme 200). Each color represents the following thickness at the center of bearing. Undersize main bearing thickness UNDERSIZE MAIN BEARING THICKNESS SPECIFICATION Color painted Bearing thickness Green & Red 2.1160 - 2.1190 mm (0.08331 - 0.08342 in.) Black & Red 2.1190 - 2.1220 mm (0.08343 - 0.08354 in.) Red only 2.1220 - 2.1250 mm (0.08355 - 0.08366 in.) Yellow & Red 2.1250 - 2.1280 mm (0.08367 - 0.08377 in.) Blue & Red 2.1280 - 2.1310 mm (0.08378 - 0.08389 in.)
2. If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. Regrind journal to the following finished diameter. Finished journal diameter 57.7380 - 57.7560 mm (2.27315 - 2.27385 in.) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round. Using journal diameter measured and alphabets stamped on lower crankcase, select an undersize bearing by referring to «UNDERSIZE BEARING SPECIFICATION TABLE»(ref-268922-S15875766252007102700000). Check bearing clearance with newly selected undersize bearing.

Undersize bearing specification

UNDERSIZE BEARING SPECIFICATION TABLE

Crankshaft Position Sensor Plate

Check teeth of plate for damage.

If any damage is found, replace crankshaft (1).

Scheme 200

Oil Pump Sprocket

Check teeth of sprocket for wear or damage.

If any damage or wear is found, replace crankshaft (1).

Scheme 201

Oil Pump Chain

Check oil pump chain for wear or damage.

Scheme 202

Flywheel

1. If ring gear is damaged, cracked or worn, replace flywheel.
2. If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.
3. Check flywheel for face runout with a dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout 0.2 mm (0.0078 in.)

Scheme 203

1. Distortion of gasketed surface.
2. Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It. Flatness Limit 0.06 mm (0.0024 in.)

Honing or reboring cylinders

1. When any cylinder needs reboring, all other cylinders must also be rebored at the same time. Oversize piston specification OVERSIZE PISTON SPECIFICATION Size Piston diameter STD 83.970 - 83.990 mm (3.3059 - 3.3067 in.) O/S 0.50 84.470 - 84.490 mm (3.3256 - 3.3264 in.)
2. Using micrometer, measure piston diameter.
3. Calculate cylinder bore diameter to be rebored as follows. D = A + B - C D: Cylinder bore diameter to be rebored. Piston diameter as measured. Piston clearance = 0.02 - 0.04 mm (0.0008 - 0.0015 in.) Allowance for honing = 0.02 mm (0.0008 in.)
4. Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install lower crankcase and tighten to specification to avoid distortion of bearing bores.
5. Measure piston clearance after honing.

Scheme 204

Check Valve

Check valve for clogging and ball for being stuck.

Scheme 205

Recommended Service Material

RECOMMENDED SERVICE MATERIAL

Note. Required service material is also described in the following: TIMING CHAIN COVER COMPONENTS , 2nd TIMING CHAIN AND CHAIN TENSIONER COMPONENTS , 1st TIMING CHAIN AND CHAIN TENSIONER COMPONENTS , CAMSHAFTS, TAPPET AND SHIM COMPONENTS , VALVES AND CYLINDER HEAD COMPONENTS , PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS COMPONENTS and MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS