Engine Mechanical: Other Suzuki SX4 I рестайлинг

Cleaning

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

Scheme 156

Throttle Body Cleaning

Reference: THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION

Clean throttle body assembly according to "Throttle Valve Visual Check" under ELECTRIC THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION .

Cam Height

Using a micrometer, measure cam height "a". If measured height is out of standard values, replace camshaft.

Cam Height (IN)

Standard: 47.023 - 47.183 mm (1.8513 - 1.8576 in.)

Limit: 46.890 mm (1.8461 in.)

Cam Height (EX)

Standard: 46.543 - 46.703 mm (1.8324 - 1.8387 in.)

Limit: 46.420 mm (1.8276 in.)

Scheme 157

Camshaft Runout

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

If measured camshaft runout exceeds limit, replace camshaft.

Camshaft runout limit

0.015 mm (0.00050 in.)

Scheme 158

Scheme 159

1. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any defective is found, replace camshaft or cylinder head with camshaft housings. CAUTION: Do not attempt to fix malcondition of camshaft journal and camshaft housing for reuse.

Scheme 160

Scheme 161

Scheme 162

1. Clean camshaft housings and camshaft journals.
2. Remove all tappets.
3. Install camshafts and lower bearing half to cylinder head.
4. Place a piece of gauging plastic to full width of camshaft journal (parallel to camshaft).
5. Install camshaft housing referring to steps 5 ) to 6 ) in "Installation" under «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(ref-514568-S02835718742012112100000) . CAUTION: Do not rotate camshaft while gauging plastic is installed.
6. Remove housings, and using scale (2) on gauging plastic envelop, measure gauging plastic (1) width at its widest point. Camshaft journal clearance (intake side of camshaft housing No. 1) Standard: 0.020 - 0.072 mm (0.00079 - 0.00283 in.) Limit: 0.10 mm (0.0039 in.) Camshaft journal clearance (except intake side of camshaft housing No. 1) Standard: 0.020 - 0.062 mm (0.00079 - 0.00244 in.) Limit: 0.095 mm (0.00374 in.) If measured camshaft journal clearance exceeds limit, recheck camshaft journal clearance according to the following procedure. Install camshaft upper bearing half and camshaft housings without camshafts to cylinder head. Tighten camshaft housing bolts referring to Step 6 ) in "Installation" under «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(ref-514568-S02835718742012112100000) . For intake camshaft journal No. 1, measure journal outside diameter at positions shown in figure. If measured diameter is out of standard values, replace camshaft and recheck camshaft journal clearance. If measured diameter is within standard values, replace camshaft bearings and recheck camshaft journal clearance. For all other camshaft journals, measure camshaft journal outside diameters and camshaft housing inside diameters. If measured diameters are out of standard values, replace corresponding camshaft or cylinder head and camshaft housings. Camshaft journal outside diameter CAMSHAFT JOURNAL OUTSIDE DIAMETER Item Standard Intake camshaft journal No. 1 "a" 28.959 - 28.980 mm (1.1402 - 1.1409 in.) Exhaust camshaft journal No. 1 26.959 - 26.980 mm (1.0614 - 1.0622 in.) Others 25.959 - 25.980 mm (1.0220 - 1.0228 in.) Camshaft housing inside diameter CAMSHAFT HOUSING INSIDE DIAMETER Item Camshaft housing No. 1 (intake) 32.000 - 32.025 mm (1.2599 - 1.2608 in.) Camshaft housing No. 1 (exhaust) 27.000 - 27.021 mm (1.0630 - 1.0638 in.) Others 26.000 - 26.021 mm (1.0237 - 1.0244 in.)
7. Install intake and exhaust camshaft without tappet, and then measure intake and exhaust camshaft housing thrust clearance using a dial gauge. If measured clearance exceeds limit, replace camshaft or cylinder head and camshaft housings. Camshaft housing thrust clearance Standard: 0.10 - 0.35 mm (0.0040 - 0.0137 in.) Limit: 0.50 mm (0.020 in.)

Wear of Tappet

Check tappet for pitting, scratches, or damage.

If any defective condition is found, replace tappet.

Scheme 163

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

Cylinder head to tappet clearance

Standard: 0.025 - 0.066 mm (0.0010 - 0.0025 in.)

Limit: 0.10 mm (0.0039 in.)

Tappet outside diameter

Standard: 32.459 - 32.475 mm (1.2780 - 1.2785 in.)

Cylinder head tappet bore

Standard: 32.500 - 32.525 mm (1.2796 - 1.2805 in.)

Scheme 164

Exhaust Camshaft Timing Sprocket

Check exhaust camshaft timing sprocket for wear and damage.

If any defective condition is found, replace exhaust camshaft timing sprocket.

Scheme 165

1. Check CMP actuator for wear or damage. If any defective condition is found, replace CMP actuator.
2. Install CMP actuator to intake camshaft and hold hexagonal section of intake camshaft stationary using wrench or the like. Check that CMP actuator (1) cannot be turned by hand. If it can be turned by hand, replace CMP actuator.

Scheme 166

Scheme 167

Oil Seal

Check oil seal lip for any damage. If abnormality is found, replace oil seal.

Timing Chain Cover

Inspect oil passage (1) for driving CMP actuator and strainer (2).

If clog or foreign matter exists, clean strainer.

Scheme 168

Timing Chain Guide

Check sliding surface of timing chain guide (1) for wear or damage.

If abnormality is found, replace timing chain guide.

Scheme 169

Timing Chain Tensioner

Check sliding surface of timing chain tensioner (1) for wear or damage.

If abnormality is found, replace timing chain tensioner.

Scheme 170

Crankshaft Timing Sprocket

Check sprocket teeth for wear or damage.

If abnormality is found, replace crankshaft timing sprocket.

Scheme 171

Timing Chain

Check timing chain for wear or damage.

If abnormality is found, replace timing chain.

Scheme 172

Timing Chain Tensioner Adjuster

Check that tooth surface (1) are free from damage.

If abnormality is found, replace timing chain tensioner adjuster.

Scheme 173

Scheme 174

Valve stem-to-guide clearance

1. Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance.
2. Be sure to take reading at more than one place along the length of each stem and guide.
3. If clearance exceeds limit, replace valve and valve guide.

Valve stem outside diameter

IN: 5.465 - 5.480 mm (0.2152 - 0.2157 in.)

EX: 5.440 - 5.455 mm (0.2142 - 0.2147 in.)

Valve guide inside diameter

IN & EX: 5.500 - 5.512 mm (0.2166 - 0.2170 in.)

Stem-to-guide clearance

Standard

IN: 0.020 - 0.047 mm (0.0008 - 0.0018 in.)

EX: 0.045 - 0.072 mm (0.0018 - 0.0028 in.)

Limit

IN: 0.070 mm (0.0027 in.)

EX: 0.090 mm (0.0035 in.)

Scheme 175

Valve stem end deflection

Check valve stem end deflection using a dial gauge.

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

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

Valve stem end deflection limit

In: 0.14 mm (0.0055 in.)

Ex: 0.18 mm (0.0070 in.)

Scheme 176

Scheme 177

1. Remove all carbon deposits from all valves (1).
2. Check each valve for wear, burn or distortion at its face and stem end. Replace it if necessary.
3. Measure valve protrusion length "a". If measured length is out of standard value, replace valve. Valve protrusion length "a" Standard IN: 44.00 - 44.60 mm (1.733 - 1.755 in.) EX: 43.55 - 44.15 mm (1.715 - 1.738 in.)

Valve head radial runout

Check each valve for radial runout using a dial gauge and "V" block.

To check runout, rotate valve slowly.

If runout exceeds its limit, replace valve.

Valve head radial runout

Standard

IN: 0.000 - 0.045 mm (0.0000 - 0.0017 in.)

EX: 0.000 - 0.030 mm (0.0000 - 0.0011 in.)

Limit

IN: 0.090 mm (0.0035 in.)

EX: 0.060 mm (0.0023 in.)

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 rotating tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used.

Pattern produced on seating surface 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

IN: 1.05 - 1.35 mm (0.0414 - 0.531 in.)

EX: 1.12 - 1.42 mm (0.0441 - 0.0559 in.)

Scheme 178

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 179

1. Intake valve seat: Use valve seat cutters to make three cuts as illustrated in figure. Three cutters must be used: the 1st for making 22° 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 "a": 1.05 - 1.35 mm (0.0414 - 0.0531 in.)
2. Exhaust valve seat: Use valve seat cutters to make three cuts as illustrated in the figure. Three cutters must be used: the 1st for making 22° angle, the 2nd for making 65° angle, and 3rd for making 45° angle. The 3rd cut must be made to produce desired seat width. Seat width for exhaust valve seat "b": 1.12 - 1.42 mm (0.0441 - 0.0559 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.

Combustion Chamber

1. Remove all carbon deposits from all combustion chambers. NOTE: Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when removing carbon deposits. The same applies to valves and valve seats, too.
2. Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface.

Cylinder Head Flatness

Using a straightedge (1) and thickness gauge (2), check flatness of gasket surface at a total of 6 locations. If any measure value exceeds its limit, correct gasket surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place abrasive paper on and over surface plate, and rub gasket surface against paper to grind off high spots.

If it is impossible to correct cylinder head distortion, replace cylinder head.

Note. Distorted mating surface of cylinder head and cylinder head gasket causes combustion gas leakage, overheating and reduced power output.

Distortion of mating surface of cylinder head and cylinder head gasket

Limit: 0.03 mm (0.0011 in.)

Scheme 180

Manifold Seating Surface Flatness

Using straightedge (1) and thickness gauge (2), check flatness of manifold seating surface.

If measured value exceeds its limit, correct seating surface or replace cylinder head.

Distortion of seating face of intake manifold and exhaust manifold on cylinder head

Limit: 0.05 mm (0.0019 in.)

Scheme 181

Valve Spring Free Length and Preload

1. Check each valve springs for breakage or weakening.
2. Measure valve spring free length and preload. If measured value is less than limit, replace valve spring. NOTE: 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 "a"

Standard: 51.34 mm (2.021 in.)

Limit: 50.34 mm (1.981 in.)

Valve spring preload when compressed to 41 mm (1.61 in.)

Standard: 170 - 196 N (17.4 kgf - 19.9 kgf, 38.3 lbf - 44.0 lbf)

Limit: 165 N (16.9 kgf, 37.1 lbf)

Valve spring preload when compressed to 31.2 mm (1.23 in.)

Standard: 379 - 437 N (38.7 - 44.5 kgf, 85.2 - 98.2 lbf)

Limit: 375 N (38.3 kgf, 84.3 lbf)

Scheme 182

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 (0.086 in.)

Scheme 183

Scheme 184

Cylinder bore diameter, taper and out-of-round

Using cylinder gauge, measure cylinder bore in thrust and axial directions.

If any of the following conditions is noted, replace cylinder block.

1. Cylinder bore exceeds limit.
2. Difference of measurements at two positions ([1] and [2]) exceeds taper limit.
3. Difference between thrust [4] and axial [3] measurements exceeds roundness limit. CAUTION: If abnormality is found on cylinder inside wall, replace cylinder block. NOTE: There are two sizes for cylinder bore, to keep clearance between piston and cylinder properly. To distinguish standard value, refer to «PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY»(ref-514568-S28980196702012112100000) .

Cylinder bore diameter

Standard

CYLINDER BORE DIAMETER

Cylinder bore diameter

Limit: 84.050 mm (3.3268 in.)

Cylinder bore roundness ([3] - [4])

Limit: 0.020 mm (0.00078 in.)

Cylinder bore taper ([1] - [2])

Limit: 0.013 mm (0.00051 in.)

Scheme 185

Scheme 186

Piston

Note. Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance.

Piston diameter

As indicated in figure, piston diameter should be measured at specified position "a" 16.0 mm (0.630 in) from piston skirt end in the direction perpendicular to piston pin.

If measured diameter is less than its limit, replace piston.

New piston diameter standard size

PISTON DIAMETER STANDARD SIZE

Piston diameter limit size

PISTON DIAMETER LIMIT SIZE

Scheme 187

Piston clearance

Measure cylinder bore diameter and piston diameter to find their difference called is piston clearance.

Piston clearance should be within its standard value.

If it is out of its limit, replace piston.

Note. Cylinder bore diameters used here are measured in thrust direction at two positions.

Piston clearance

Limit: 0.12 mm (0.0047 in.)

Ring groove clearance

Scheme 188

1. Before checking, piston grooves must be clean, dry and free from carbon deposits.
2. Fit new piston ring (1) into piston groove.
3. Measure clearance between ring and ring land using thickness gauge (2). If clearance is out of limit, replace piston. Ring groove clearance RING GROOVE CLEARANCE Standard Limit 1st ring 0.03 - 0.07 mm (0.0012 - 0.0027 in.) 0.11 mm (0.0043 in.) 2nd ring 0.02 - 0.06 mm (0.0008 - 0.0023 in.) 0.11 mm (0.0043 in.) Oil ring 0.03 - 0.17 mm (0.0012 - 0.0066 in.)

Piston ring end gap

To measure end gap, insert piston ring (1) into cylinder bore and then measure the gap using thickness gauge (2).

If measured gap exceeds limit, replace piston ring.

Note. Remove carbon deposit from and clean top of cylinder bore before inserting piston ring.

Piston ring end gap

PISTON RING END GAP REFERENCE CHART

Scheme 189

Piston pin clearance

Check piston pin clearance in connecting rod small-end and piston. Replace connecting rod and/or piston if its small-end is badly worn or damaged or if measured clearance exceeds limit.

Piston pin clearance in connecting rod small-end

Standard: 0.003 - 0.016 mm (0.00012 - 0.00062 in.)

Limit: 0.040 mm (0.0015 in.)

Piston pin clearance in piston

Standard: 0.006 - 0.017 mm (0.00024 - 0.00066 in.)

Limit: 0.05 mm (0.0019 in.)

Small-end bore

21.003 - 21.013 mm (0.82689 - 0.82728 in.)

Piston pin outside diameter

20.997 - 21.000 mm (0.82666 - 0.82677 in.)

Diameter of piston pin hole in piston

21.006 - 21.014 mm (0.82701 - 0.82732 in.)

Scheme 190

Big-end side clearance

Check big-end side clearance of connecting rod, with rod fitted and connected to its crankshaft pin in the normal manner.

If measured clearance is out of its standard value, replace connecting rod.

Big-end side clearance

Standard: 0.25 - 0.40 mm (0.0099 - 0.0157 in.)

Scheme 191

Connecting rod bolt deformation

Measure each thread, diameter of connecting rod bolt (1) "A" at "a" and "B" at "b" using a micrometer (3).

Calculate difference in diameters ("A" - "B").

If it is exceeds limit, replace connected rod (1).

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"): 0.05 mm (0.0019 in.)

Scheme 192

Crankshaft Pin Diameter

1. Using micrometer, measure crankshaft pin diameter at several points and calculate taper and out-of-round conditions. If calculated taper and/or out-of-round is out of their service limit, replace crankshaft or regrind crankshaft pin to undersize and use undersize bearing. CAUTION: If crankshaft pin is reground, new undersize bearings must be installed and bearing clearance must be checked.

Crankshaft pin diameter

Standard: 49.982 - 50.000 mm (1.96780 - 1.96850 in)

Crankshaft pin taper ([a] -[b]) and out-of-round ([1] -[2])

Limit: 0.01 mm (0.0003 in.)

Scheme 193

Scheme 194

1. Service connecting rod bearings are available in five standard sizes and 0.25 mm (0.0098 in) undersize bearing. The difference of those sizes is thickness.
2. Specified colors for identification of sizes are painted at specified location (1) as shown in figure. BEARING THICKNESS SPECIFICATIONS Painted color Bearing thickness Standard size Blue 1.494 - 1.497 mm (0.05882 - 0.05893 in.) Yellow 1.491 - 1.494 mm (0.05871 - 0.05881 in.) Colorless 1.488 - 1.491 mm (0.05859 - 0.05870 in.) Black 1.485 - 1.488 mm (0.05847 - 0.05858 in.) Green 1.482 - 1.485 mm (0.05835 - 0.05846 in.) 0.25 mm (0.0098 in) undersize Red 1.605 - 1.615 mm (0.06319 - 0.06358 in.)

Connecting Rod Bearing Clearance

Note. After checking connecting rod bearing clearance, check connecting rod bolt for deformation referring to " CONNECTING ROD DEFORMATION " under PISTON PINS AND CONNECTING RODS INSPECTION .

Scheme 195

Scheme 196

1. Clean connecting rod bearings and crankshaft pin.
2. Place a piece of gauging plastic (1) to full width of crankshaft pin as contacted by bearing (parallel to crankshaft), avoiding oil hole.
3. Install connecting rod bearings and its cap, see «Piston, Piston Ring and Connecting Rod Removal and Installation»(ref-514568-S30615370172012112100000) .
4. After three minutes elapsed, remove cap and using a scale (2) on gauging plastic envelope, measure gauging plastic (1) width at the widest point. Connecting rod bearing clearance Standard: 0.045 - 0.063 mm (0.0018 - 0.0024 in.) Limit: 0.065 mm (0.0025 in.) If measured oil clearance is less than standard value or more than service limit, replace connecting rod bearings with new ones referring to «SELECTION OF CONNECTING ROD BEARINGS»(ref-514568-S35759652562012112100000) , and recheck oil clearance. Depending on measured oil clearance with new bearing, select other bearings according to the following procedures, and recheck oil clearance. More than standard: Replace bearings with one size thicker or regrind crankshaft pin to under size and use 0.25 mm (0.0098 in) undersize bearings. Less than standard: Replace bearings with one size thinner or regrind crankshaft pin to under size and use 0.25 mm (0.0098 in) undersize bearings.

Scheme 197

Scheme 198

1. Check connecting rod big-end inside diameter according to the following procedures. There is stamped number (any of "1", "2" or "3") on each connecting rod and it cap as shown in figure. That number represent connecting rod big-end inside diameter as follows. Connecting rod big-end inside diameter CONNECTING ROD BIG-END INSIDE DIAMETER SPECIFICATIONS Stamped number Connecting rod big-end inside diameter 1 53.0000 - 53.0060 mm (2.08662 - 2.08685 in.) 2 53.0061 - 53.0120 mm (2.08686 - 2.08708 in.) 3 53.0121 - 53.0180 mm (2.08710 - 2.08732 in.)
2. Check crankshaft pin diameter according to the following procedures. There are four stamped alphabets (any of "A", "B" or "C") on crank web No. 5 as shown in figure. Those alphabets represent crankshaft pin diameter as follows. Crankshaft pin diameter CRANKSHAFT PIN DIAMETER SPECIFICATIONS Stamped alphabet Crankshaft pin diameter A 49.9940 - 50.0000 mm (1.96827 - 1.96850 in.) B 49.9880 - 49.9939 mm (1.96804 - 1.96826 in.) C 49.9820 - 49.9879 mm (1.96780 - 1.96802 in.)
3. From numbers stamped on connecting rods and its caps and alphabets stamped on crank web No. 5, determine new standard bearings to be installed to connecting rod big-end from the following table. Connecting rod bearing cross-reference selection table CONNECTING ROD BEARING CROSS-REFERENCE SELECTION TABLE Stamped number for connecting rod big-end inside diameter 1 2 3 Stamped alphabet for Crankshaft pin outside diameter A Green Black Colorless B Black Colorless Yellow C Colorless Yellow Blue

Scheme 199

1. Determine target diameter of crankshaft pin for regrinding according to the following procedure. Assemble connecting rod, connecting rod cap and undersize bearings (0.25 mm), referring to step 2) to 5) of "Installation" under Piston, «Piston, Piston Ring and Connecting Rod Removal and Installation»(ref-514568-S30615370172012112100000) . Using bore gauge, measure connecting rod bearing inside diameter "a". Calculate target diameter according to formula below. Formula for target diameter of crankshaft pin A = B - 0.054 mm (0.0021 in.) Target diameter of crankshaft pin Measured connecting rod bearing inside diameter "a" .
2. Grind crankshaft pin to target diameter.
3. Check connecting rod bearing oil clearance, see «Connecting Rod Bearing Clearance»(ref-514568-S38645009682012112100000) .

Scheme 200

Crankshaft Runout

Using dial gauge, measure runout at center journal. Rotate crankshaft slowly.

If runout exceeds its limit, replace crankshaft.

Crankshaft runout

Limit: 0.02 mm (0.0007 in.)

Scheme 201

Scheme 202

1. Assemble crankshaft, main bearings, thrust bearings and lower crank case. See «Main Bearings, Crankshaft and Cylinder Block Removal and Installation»(ref-514568-S27512620702012112100000) .
2. Using dial gauge (1), measure crankshaft thrust play (2) as shown in figure. If measured thrust play is out of standard value, replace thrust bearing with new one (standard size or over size) to obtain standard thrust play. Recheck crankshaft thrust play. Crankshaft thrust play Standard: 0.10 - 0.35 mm (0.0040 - 0.0137 in.) Thrust bearing thickness Standard size: 2.470 - 2.520 mm (0.0973 - 0.0992 in.) Oversize (0.125 mm, 0.00492 in.): 2.533 - 2.583 mm (0.0998 - 0.1016 in.)

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 uneven wear exceeds its limit, regrind or replace crankshaft.

Crankshaft journal outside diameter

Standard: 51.982- 52.000 mm (2.0466 - 2.0472 in)

Limit: 51.972 mm (2.0461 in.)

Crankshaft out-of-round (A - B) and taper (a - b)

Limit: 0.01 mm (0.0003 in.)

Scheme 203

Main Bearing Clearance

Note. After checking main bearing clearance, check crank case bolt No. 1 for deformation. See Crank Case Bolt No. 1 Inspection .

Scheme 204

Scheme 205

1. Remove lower crank case.
2. Clean bearings and crankshaft journals.
3. Place a piece of gauging plastic (1) over the full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
4. Install lower crank case, see «Main Bearings, Crankshaft and Cylinder Block Removal and Installation»(ref-514568-S27512620702012112100000) .
5. After three minutes, remove lower crank case and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. NOTE: If pair of crankshaft journal and cylinder block journal is in the following condition, different values are applied as standard. Stamped number for crankshaft journal diameter is "4", and stamped alphabet for cylinder block journal inside diameter is "A". Standard: 0.019 - 0.031 mm (0.00075 - 0.00122 in.) Stamped number for crankshaft journal diameter is "9", and stamped alphabet for cylinder block journal inside diameter is "F". Standard: 0.025 - 0.037 mm (0.00098 - 0.00145 in.) For more information about stamped number and stamped alphabet, refer to «SELECTION OF MAIN BEARINGS»(ref-514568-S39856679242012112100000) . Main bearing clearance Standard: 0.022 - 0.034 mm (0.00087 - 0.00133 in.) Limit: 0.050 mm (0.00196 in.) If measured clearance is less than standard or more than service limit, replace main bearings with new ones referring to «SELECTION OF MAIN BEARINGS»(ref-514568-S39856679242012112100000) and recheck main bearing clearance. If measured clearance with new bearings is out of standard, select other bearings according to the following procedures and recheck main bearing clearance. More than standard: Replace bearing with one size thicker or regrind crank shaft journal to undersize and use 0.25 mm undersize bearing (0.0098 in). Less than standard: Replace bearing with one size thinner or regrind crank shaft journal to undersize and use 0.25 mm undersize bearing (0.0098 in).

Standard size bearing

If engine is under one of the following conditions, select a new standard bearings as follows, and install it.

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

Scheme 206

Scheme 207

Scheme 208

1. Check crankshaft journal diameter according to the following procedures. There are five stamped numbers (any of "4" through "9") on crank web No. 4 as shown in figure. Those numbers represent crankshaft journal diameter as follows. Determine crankshaft journal diameter for journals No. 1 through No. 5 using stamped numbers and following table. Crankshaft journal diameter CRANKSHAFT JOURNAL DIAMETER SPECIFICATIONS Stamped number Journal diameter 4 51.997 - 52.000 mm (2.04713 - 2.04724 in.) 5 51.994 - 51.997 mm (2.04701 - 2.04712 in.) 6 51.991 - 51.994 mm (2.04689 - 2.04700 in.) 7 51.988 - 51.991 mm (2.04678 - 2.04688 in.) 8 51.985 - 51.988 mm (2.04666 - 2.04677 in.) 9 51.982 - 51.985 mm (2.04654 - 2.04665 in.)
2. Check cylinder block journal inside diameter according to the following procedures. There are five stamped alphabets (6) (any of "A" through "F") on lower crank case as shown in figure. Those alphabets represent cylinder block journal inside diameter as follows. Determine cylinder block journal inside diameter for journals No. 1 through No. 5 using stamped alphabets and following table. CYLINDER BLOCK JOURNAL INSIDE DIAMETER FOR JOURNALS REFERENCE CHART Stamped alphabet Cylinder block journal in side diameter A 56.000 - 56.003 mm (2.20473 - 2.20484 in.) B 56.003 - 56.006 mm (2.20485 - 2.20496 in.) C 56.006 - 56.009 mm (2.20496 - 2.20507 in.) D 56.009 - 56.012 mm (2.20508 - 2.20519 in.) E 56.012 - 56.015 mm (2.20520 - 2.20531 in.) F 56.015 - 56.018 mm (2.20532 - 2.20543 in.)
3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as shown in figure. Each color indicated the following thickness at the center of bearing. Standard size crankshaft main bearing thickness STANDARD SIZE CRANKSHAFT MAIN BEARING THICKNESS SPECIFICATIONS Painted color Bearing thickness Blue 2.011 - 2.014 mm (0.07918 - 0.07929 in) Yellow 2.008 - 2.011 mm (0.07906 - 0.07917 in) Colorless 2.005 - 2.008 mm (0.07894 - 0.07905 in) Black 2.002 - 2.005 mm (0.07882 - 0.07893 in) Green 1.999 - 2.002 mm (0.07870 - 0.07881 in)
4. Select new standard crankshaft bearings using stamped numbers for crankshaft journal diameter, stamped alphabets for cylinder block journal inside diameter and following table. Main bearing cross - reference selection table (standard size) MAIN BEARING CROSS - REFERENCE SELECTION TABLE (STANDARD SIZE) Stamped number on crank web No. 4 4 5 6 7 8 9 Stamped alphabets on lower crank case A Upper Green Green Green Black Black Colorless Lower Green Green Black Black Colorless Colorless B Upper Green Green Black Black Colorless Colorless Lower Green Black Black Colorless Colorless Yellow C Upper Green Black Black Colorless Colorless Yellow Lower Black Black Colorless Colorless Yellow Yellow D Upper Black Black Colorless Colorless Yellow Yellow Lower Black Colorless Colorless Yellow Yellow Blue E Upper Black Colorless Colorless Yellow Yellow Blue Lower Colorless Colorless Yellow Yellow Blue Blue F Upper Colorless Colorless Yellow Yellow Blue Blue Lower Colorless Yellow Yellow Blue Blue Blue

Scheme 209

Scheme 210

1. 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in figure. Each color represents the following thickness at the center of bearing. Undersize of crankshaft main bearing thickness UNDERSIZE OF CRANKSHAFT MAIN BEARING THICKNESS SPECIFICATIONS Painted color Bearing thickness Red & Blue 2.136 - 2.139 mm (0.08410 - 0.08421 in.) Red & Yellow 2.133 - 2.136 mm (0.08398 - 0.08409 in.) Red 2.130 - 2.133 mm (0.08386 - 0.08397 in.) Red & Black 2.127 - 2.130 mm (0.08374 - 0.08385 in.) Red & Green 2.124 - 2.127 mm (0.08362 - 0.08374 in.)
2. If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. Regrind crankshaft journal to the following finished diameter. Finished crankshaft journal diameter 51.732 - 51.750 mm (2.03670 - 2.03740 in.) Using micrometer, measure reground journal diameter. See «Crankshaft Inspection»(ref-514568-S03986909892012112100000) . Using measured journal diameter above and alphabets stamped on cylinder block, select an undersize bearing by referring to the following table. Main bearing cross - reference table (under size) MAIN BEARING CROSS - REFERENCE TABLE (UNDER SIZE) Measured journal diameter 51.7470 - 51.7499 (2.03728 - 2.03739 in.) 51.7440 - 51.7469 (2.03717 - 2.03727 in.) 51.7410 - 51.7439 (2.03705 - 2.03716 in.) 51.7380 - 51.7409 (2.03693 - 2.03704 in.) 51.7350 - 51.7379 (2.03681 - 2.03692 in.) 51.7320 - 51.7349 (2.03669 - 2.03680 in.) Stamped alphabet on lower crank case A Upper Red & Green Red & Green Red & Green Red & Black Red & Black Red Lower Red & Green Red & Green Red & Black Red & Black Red Red B Upper Red & Green Red & Green Red & Black Red & Black Red Red Lower Red & Green Red & Black Red & Black Red Red Red & Yellow C Upper Red & Green Red & Black Red & Black Red Red Red & Yellow Lower Red & Black Red & Black Red Red Red & Yellow Red & Yellow D Upper Red & Black Red & Black Red Red Red & Yellow Red & Yellow Lower Red & Black Red Red Red & Yellow Red & Yellow Red & Blue E Upper Red & Black Red Red Red & Yellow Red & Yellow Red & Blue Lower Red Red Red & Yellow Red & Yellow Red & Blue Red & Blue F Upper Red Red Red & Yellow Red & Yellow Red & Blue Red & Blue Lower Red Red & Yellow Red & Yellow Red & Blue Red & Blue Red & Blue Install selected main bearings and measure bearing clearance, see «Main Bearing Clearance»(ref-514568-S16781733582012112100000) . If measured clearance is more than standard, replace bearings with one size thicker and recheck bearing clearance. If measured clearance is less than standard, replace bearings with one size thinner and recheck bearing clearance.

Oil Pump Chain

Check oil pump chain for wear or any damage.

If malcondition is found, replace oil pump chain.

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Flywheel/Drive Plate Face Runout

1. Check flywheel for M/T model or drive plate for CVT model for runout using dial gauge and "V" blocks. If measured runout exceeds its limit, replace flywheel for M/T model or drive plate for CVT model.

Flywheel/drive plate face runout

Limit: 0.2 mm (0.0078 in.)

Scheme 212

Distortion of Gasket Surface

Using straightedge and thickness gauge, check gasket surface for distortion and, if flatness exceeds its limit, repair It.

If repair is not possible, replace cylinder block.

Cylinder block flatness

Limit: 0.03 mm (0.001 in.)

Scheme 213

Recommended Service Material

RECOMMENDED SERVICE MATERIAL REFERENCE CHART

Note. Required service material is also described in the following. CYLINDER HEAD COVER COMPONENTS CAMSHAFT AND TAPPET COMPONENTS TIMING CHAIN COVER COMPONENTS TIMING CHAIN AND CHAIN TENSIONER COMPONENTS VALVE AND CYLINDER HEAD COMPONENTS PISTON, PISTON RING AND CONNECTING ROD COMPONENTS MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS