Page 2001 of 5121

EM-126
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-130, "
ConnectingRodBearing".
Method of Using Plastigage
Remove oil and dust on crankshaft pin 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 connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-110, "
Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Never rotate crankshaft.
Remove connecting rod bearing cap and bearings, and using the
scale 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
caps (2), and main bearing cap bolts with main bearing beam to
the specified torque. Refer to EM-110, "
Disassembly and Assem-
bly" for the tightening procedure.
Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)
If the calculated value exceeds the limit, select proper main bear-
ing according to main bearing inner diameter and crankshaft main
journal diameter to obtain the specified bearing oil clearance.
Refer to EM-132, "
MainBearing".
Method of Using Plastigage
Remove engine oil and dust on crankshaft 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 bearing to cylinder block and main bearing caps, and tighten main bearing cap bolts with main
bearing beam to the specified torque. Refer to EM-110, "
Disassembly and Assembly" for the tightening pro-
cedure.
CAUTION:
Never rotate crankshaft.
JPBIA0231ZZ
Standard and limit : Refer to EM-146, "MainBearing".
JPBIA0232ZZ
Page 2002 of 5121

CYLINDER BLOCK
EM-127
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
Remove main bearing caps and bearings, and using the scale 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. Refer to EM-110, "
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-110, "
Disassem-
bly and Assembly" for the tightening procedure.
If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT OUTER DIAMETER
Measure the outer diameters (c), (d) at two positions as shown in
the figure.
If reduction appears in (a) range, regard it (c).
If it exceeds the limit (large difference in dimensions), replace main
bearing cap bolt with new one.
CONNECTING ROD BOLT OUTER DIAMETER
JPBIA0231ZZ
A : Crush height
Standard : There must be crush height.
JPBIA0233ZZ
A : Crush height
Standard : There must be crush height.
JPBIA0233ZZ
a : 20 mm (0.79 in)
b : 30 mm (1.18 in)
e : 10 mm (0.39 in)
Limit [(d) – (c)] : 0.11 mm (0.0043 in)
JPBIA0234ZZ
Page 2003 of 5121

EM-128
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Measure the outer diameter (d) at position shown in the figure.
If the 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 new one.
DRIVE PLATE
Check drive plate and signal plate for deformation or damage.
CAUTION:
Never disassemble drive plate.
Never place drive plate with signal plate facing down.
When handling signal plate, take care not to damage or
scratch it.
Handle signal plate in a manner that prevents it from becom-
ing magnetized.
If anything is found, replace drive plate.
OIL JET (VQ35DE)
Check nozzle for deformation and damage.
Blow compressed air from nozzle, and check for clogs.
If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE (VQ35DE)
Using a clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force.
If it is not satisfied, replace oil jet relief valve.Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 in)
Limit : 7.75 mm (0.3051 in)
PBIC0912E
JPBIA0192ZZ
EMU0468D
Page 2004 of 5121

HOW TO SELECT PISTON AND BEARING
EM-129
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
HOW TO SELECT PISTON AND BEARING
DescriptionINFOID:0000000003802296
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
PistonINFOID:0000000003802297
WHEN NEW CYLINDER BLOCK IS USED
Check the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinder
block, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)
WHEN NEW CYLINDER BLOCK IS REUSED
1. Measure the cylinder bore inner diameter. Refer to EM-119, "Inspection".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “PISTON SELECTION TABLE”.
Selection points Selection parts Selection items Selection methods
Between cylinder block and
crankshaftMain bearingMain bearing grade
(bearing thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft and con-
necting rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer di-
ameter determine connecting
rod bearing selection.
Between cylinder block and pis-
tonPiston and piston pin assembly
(Piston is available together
with piston pin as assembly.)Piston grade
(piston skirt diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
Between piston and connecting
rod*———
SEM756G
Page 2005 of 5121

EM-130
< DISASSEMBLY AND ASSEMBLY >
HOW TO SELECT PISTON AND BEARING
VQ25DE
VQ35DE
3. Select piston of the same grade.
PISTON SELECTION TABLE
VQ25DE
Unit: mm (in)
VQ35DE
Unit: mm (in)
NOTE:
Piston is available together with piston pin as assembly.
Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-
ton pin grades can be selected. (Only “0” grade is available.)
No second grade mark is available on piston.
Connecting Rod BearingINFOID:0000000003802298
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
A : Piston grade number
B : Front mark
C : Piston pin grade
D : Identification code
JPBIA2198ZZ
A : Piston grade number
B : Front mark
C : Piston pin grade
D : Identification code
JPBIA2199ZZ
Grade 1 2 3
Cylinder bore inner diameter85.000 - 85.010
(3.3465 - 3.3468)85.010 - 85.020
(3.3468 - 3.3472)85.020 - 85.030
(3.3472 - 3.3476)
Piston skirt diameter84.980 - 84.990
(3.3457 - 3.3461)84.990 - 85.000
(3.3461 - 3.3465)85.000 - 85.010
(3.3465 - 3.3468)
Grade 1 2 3
Cylinder bore inner diameter95.500 - 95.510
(3.7598 - 3.7602)95.510 - 95.520
(3.7602 - 3.7606)95.520 - 95.530
(3.7606 - 3.7610)
Piston skirt diameter95.480 - 95.490
(3.7590 - 3.7594)95.490 - 95.500
(3.7594 - 3.7598)95.500 - 95.510
(3.7598 - 3.7602)
Page 2006 of 5121

HOW TO SELECT PISTON AND BEARING
EM-131
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
Check pin diameter grade (“0”, “1” or “2”) on front of crankshaft,
and select connecting rod bearing of the same grade.
NOTE:
There is no grading for connecting rod big end diameter.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the connecting rod big end diameter. Refer to EM-119, "Inspection".
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-119, "
Inspection".
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in
“Crankshaft pin journal diameter” column of “CONNECTING ROD BEARING SELECTION TABLE”.
5. Select connecting rod bearing of the same grade.
CONNECTING ROD BEARING SELECTION TABLE
VQ25DE
Unit: mm (in)
Unit: mm (in)
VQ35DE
Unit: mm (in)
Unit: mm (in)
CONNECTING ROD BEARING GRADE TABLE
UNDERSIZE BEARING USAGE GUIDE
When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
A : Journal diameter grade No. 1
B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification
JPBIA0269ZZ
Connecting rod big end diameter 48.000 - 48.013 (1.8898 - 1.8903)
Crankshaft Connecting rod bearing
Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
44.968 - 44.974 (1.7704 - 1.7706) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
44.962 - 44.968 (1.7702 - 1.7704) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
44.956 - 44.962 (1.7699 - 1.7702) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green
Connecting rod big end diameter 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft Connecting rod bearing
Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
51.962 - 51.968 (2.0457 - 2.0460) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
51.956 - 51.962 (2.0455 - 2.0457) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green
Connecting rod bearing grade table : Refer to EM-147, "ConnectingRodBearing".
Page 2007 of 5121

EM-132
< DISASSEMBLY AND ASSEMBLY >
HOW TO SELECT PISTON AND BEARING
When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind 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 (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].
Main BearingINFOID:0000000003802299
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED
1. “MAIN BEARING SELECTION TABLE” rows correspond to
bearing housing grade on rear left side of cylinder block.
2. “MAIN BEARING SELECTION TABLE” columns correspond to
journal diameter grade on front side of crankshaft.
3. Select main bearing grade at the point where selected row and column meet in “MAIN BEARING SELEC-
TION TABLE”.
4. Apply sign at crossing in above step 3 to “MAIN BEARING GRADE TABLE”.
NOTE:
“MAIN BEARING GRADE TABLE” applies to all journals.
Service parts is available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-119, "
Inspection".
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“MAIN BEARING SELECTION TABLE”.Bearing under-
size table: Refer to EM-147,
"ConnectingRodBearing".
JPBIA0216ZZ
SEM756G
A : Journal diameter grade No. 1
B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification code
JPBIA0269ZZ
Page 2008 of 5121
HOW TO SELECT PISTON AND BEARING
EM-133
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “MAIN BEARING
SELECTION TABLE”.
4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used”.
MAIN BEARING SELECTION TABLE
MAIN BEARING GRADE TABLE (ALL JOURNALS)
UNDERSIZE BEARING USAGE GUIDE
When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
PBIC5332E
Main bearing grade table (All journals) : Refer to EM-146, "MainBearing".