EM-222
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
ENGINE UNIT
Check with a connecting rod aligner.
If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END DIAMETER
Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod bolts to the specified
torque. Refer to EM-212, "
Disassembly and Assembly" for the
tightening procedure.
Measure the inner diameter of connecting rod big end with an
inside micrometer.
If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
Piston Pin Outer Diameter
C : Feeler gauge
Bend (A):
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
To r s i o n ( B ) :
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
PBIC3268J
2 : Connecting rod
A : Example
B : Measuring direction of inner diameter
Standard: 47.000 - 47.013 mm (1.8504 - 1.8509 in)
PBIC3269J
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC3270J
ENGINE UNIT
EM-223
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
Measure the outer diameter of piston pin with a micrometer (A).
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
If replacing piston and piston pin assembly, refer to "PISTON TO PISTON PIN OIL CLEARANCE".
If replacing connecting rod assembly, refer to "Connecting Rod Bushing Oil Clearance" to select connecting
rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION
Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler
gauge (B).
If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-212, "
Disassembly and Assembly" for the tightening procedure.
Measure the inner diameter of main bearing housing with a bore gauge.
Measure the position shown [5 mm (0.20 in)] backward from main
bearing housing front side in the 2 directions as shown. The
smaller one is the measured value.
If out of the standard, replace cylinder block and main bearing
caps assembly.
NOTE:
Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block. Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)
PBIC3266J
Standard : 0.005 - 0.023 mm (0.0002 - 0.0009 in)
Limit : 0.03 mm (0.0012 in)
Limit: 0.1 mm (0.004 in)
PBIC3250J
1 : Cylinder block
2 : Main bearing cap
: Engine front
Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in)
PBIC4005E
ENGINE UNIT
EM-225
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
Measure the outer diameter of crankshaft main journals with a
micrometer (A).
If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to "MAIN BEARING OIL
CLEARANCE".
CRANKSHAFT PIN JOURNAL DIAMETER
Measure the outer diameter of crankshaft pin journal with a micrometer.
If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to "CONNECTING ROD BEARING OIL CLEARANCE".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
Measure the dimensions at four different points as shown on each
main journal and pin journal with a micrometer.
Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”.
Taper is indicated by the difference in dimension between “A” and
“B” at “X” and “Y”.
If the measured value exceeds the limit, correct or replace crankshaft.
If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to "MAIN BEARING OIL CLEARANCE" and/or "CON-
NECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
Place a dial indicator (A) straight up on the No. 3 journal.
While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)
If it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
Standard: 51.959 - 51.979 mm (2.0456 - 2.0464 in) dia.
PBIC3457J
Standard: 43.953 - 43.971 mm (1.7304-1.7311 in) dia.
Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.0035 mm (0.0001 in)
Taper (Difference between “A” and “B”)
: 0.0035 mm (0.0001 in)
PBIC3459J
Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0040 in)
PBIC3458J
EM-226
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
ENGINE UNIT
Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod bolts to the
specified torque. Refer to EM-212, "
Disassembly and Assembly"
for tightening procedure.
Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-230,
"How to Select Piston and Bearing".
Method of Using Plastigage
Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-212, "
Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-212, "
Disassembly and Assembly" for the tightening
procedure.
Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
A : Example
B : Inner diameter measuring direction
Standard : 0.037 - 0.047 mm (0.0015 - 0.0019 in)
Limit : 0.07 mm (0.0028 in)
PBIC3275J
PBIC3276J
A : Example
B : Inner diameter measuring direction
Standard:
No. 1, 4 and 5 journals
: 0.024 - 0.034 mm (0.0009 - 0.0013 in)
No. 2 and 3 journals
: 0.012 - 0.022 mm (0.0005 - 0.0009 in)
Limit : 0.065 mm (0.0026 in)
PBIC3277J
ENGINE UNIT
EM-227
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-230, "
How to Select
Piston and Bearing".
Method of Using Plastigage
Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec-
ified torque. Refer to EM-212, "
Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING CRUSH HEIGHT
When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-212, "
Disassembly and
Assembly" for the tightening procedure.
If the standard is not met, replace main bearings.
CONNECTING ROD BEARING CRUSH HEIGHT
When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-212, "
Disassem-
bly and Assembly" for the tightening procedure (B).
If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT OUTER DIAMETER
PBIC3278J
A : Example
Standard : There must be crush height.
PBIC3279J
A : Example
Standard : There must be crush height.
PBIC3279J
EM-228
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
ENGINE UNIT
Measure the outer diameters (“d1”, “d2”) at two positions as shown.
If reduction appears in places other than “B” range, regard it as
“d
2”.
If it exceeds the limit (a large difference in dimensions), replace
main bearing cap bolt with a new one.
CONNECTING ROD BOLT OUTER DIAMETER
Measure the outer diameter “d” at position as shown.
If reduction appears in a position other than “d”, regard it as “d”.
When “d” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with a new one.
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)
Make sure that there is no foreign material on the oil filter and
check it for clogging.
- Clean it if necessary.
Check the oil filter for damage.
- Replace it if necessary.
FLYWHEEL DEFLECTION (M/T MODELS)
Measure the deflection of flywheel contact surface to clutch with a
dial indicator (A).
Measure the deflection at 210 mm (8.27 in) diameter.
If measured value is out of the standard, replace flywheel.
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)
CAUTION:
Never disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
A : “d1” measuring position
B : “d2” measuring position
Limit (“d1” – “d2”): 0.15 mm (0.0059 in)
PBIC4015E
Limit: 7.75 mm (0.3051 in)
PBIC4016E
PBIC3273J
Limit : 0.45 mm (0.0177 in) or less.
PBIC4006E
Standard : 1.8 mm (0.071 in) or less
HOW TO SELECT PISTON AND BEARING
EM-231
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
3. Select piston of the same grade.
Piston Selection Table
Unit: mm (in)
NOTE:
Piston is available together with piston pin as an assembly.
There is no piston pin (piston pin hole) grade.
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
1. Apply connecting rod big end diameter grade stamped (C) on
connecting rod side face to the row in the “Connecting Rod
Bearing Selection Table”.
2. Apply crankshaft pin journal diameter grade stamped on crank-
shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
When Crankshaft and Connecting Rod are Reused
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-219, "
Inspection After Disassembly" and EM-219, "Inspection After Disassembly".
A : Identification code
B : Front mark
C : Piston grade number
D : Sub grade number
PBIC3589J
Grade number (Mark) 1 2 [or no mark (piston only)]
Cylinder bore Inner diameter 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079)
Piston skirt diameter 83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067)
A : Oil hole
B : Cylinder number
D : Small end diameter grade
E : Front mark
PBIC3262J
A : No. 1 pin journal diameter grade
B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade
G : No. 3 main journal diameter grade
H : No. 4 main journal diameter grade
I : No. 5 main journal diameter grade
PBIC3261J
HOW TO SELECT PISTON AND BEARING
EM-233
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O Undersize Bearings Usage Guide
When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
Bearing undersize table
Unit: mm (in)
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
01UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
Grade and color are different
between upper and lower bear-
ings. LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
12UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green
23UPR 1.500 - 1.503 (0.0591 - 0.0592) Green
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue Grade number Thickness Identification color Remarks
PBIC3263J
Size Thickness
US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642)