ENGINE UNIT INSPECTION


  1. INSPECT OIL NOZZLE


    1. Check the oil nozzles for damage or clogging.

      If necessary, replace the oil nozzle.

  2. INSPECT CHAIN


    1. A01J3SQE03

      Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

    2. Using a vernier caliper, measure the length of 16 links.

      Maximum chain elongation
      147.5 mm (5.807 in.)

      If the elongation is greater than the maximum, replace the chain.

      Note

      Make the same measurement pulling at 3 or more places selected at random. Average the measurements.

  3. INSPECT NO. 2 CHAIN


    1. A01J3SQE03

      Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

    2. Using a vernier caliper, measure the length of 16 links.

      Maximum chain elongation
      123.6 mm (4.866 in.)

      If the elongation is greater than the maximum, replace the chain.

      Note

      Make the same measurement pulling at 3 or more places selected at random. Average the measurements.

  4. INSPECT CAMSHAFT TIMING GEAR (VVT CONTROLLER)


    1. A01J6OUE02

      Check the lock of the camshaft timing gear.


      1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

        Note

        Be careful not to damage the camshaft.

    2. Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

      2. Break through the tape of the advance side path and the retard side path on the opposite side of the groove.

      3. A01J7K7E03

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the paths whose tape was broken in the procedure above.

        CAUTION:

        Some oil spraying will occur. Contain the spray with a shop rag.

      4. A01J3U9E04

        Check that the camshaft timing gear revolves in the advance direction when weakening the air pressure of the retard side path.

        OK
        Gear rotates in advance direction.

        Tech Tips

        This operation releases the lock pin for the extreme retard position.

      5. When the camshaft timing gear reaches the extreme advance position, remove the air gun from the retard side path and advance side path, in that order.

        Note

        Do not remove the air gun from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    3. Check for smooth rotation.


      1. Rotate the camshaft timing gear within its movable range several times, but do not turn it to the extreme retard position. Check that the gear rotates smoothly.

        OK
        Gear rotates in advance direction.

        Note

        Do not use an air gun to perform the smooth operation check.

    4. Check the lock in the extreme retard position.


      1. Confirm that the camshaft timing gear is locked at the extreme retard position.

  5. INSPECT NO. 1 CAMSHAFT


    1. A01J5VRE01

      Check the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.03 mm (0.0012 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. A01J64QE01

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      42.855 to 42.955 mm (1.6872 to 1.6911 in.)
      Minimum cam lobe height
      42.855 mm (1.6872 in.)

      If the cam lobe height is less than the minimum, replace the camshaft.

    3. A01J7BFE01

      Using a micrometer, measure the journal diameter.

      Standard journal diameter
      Item Specified Condition
      No. 1 journal 35.949 to 35.965 mm (1.4153 to 1.4159 in.)
      Other journal 26.959 to 26.975 mm (1.0614 to 1.0620 in.)

      If the journal diameter is not as specified, check the oil clearance.

  6. INSPECT NO. 2 CAMSHAFT


    1. A01J31VE01

      Check the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.03 mm (0.0012 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. A01J64QE02

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      42.854 to 42.954 mm (1.687 to 1.6911 in.)
      Minimum cam lobe height
      42.854 mm (1.6872 in.)

      If the cam lobe height is less than the minimum, replace the camshaft.

    3. A01J7BFE01

      Using a micrometer, measure the journal diameter.

      Standard journal diameter
      Item Specified Condition
      No. 1 journal 35.949 to 35.965 mm (1.4153 to 1.4159 in.)
      Other journal 26.959 to 26.975 mm (1.0614 to 1.0620 in.)

      If the journal diameter is not as specified, check the oil clearance.

  7. INSPECT NO. 1 CHAIN TENSIONER


    1. A01J7LDE03

      Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.

  8. INSPECT NO. 2 CHAIN TENSIONER


    1. A01J6PRE02

      Move the stopper plate downward to release the lock.

      Push the plunger and check that it moves smoothly.

  9. INSPECT CAMSHAFT TIMING SPROCKET


    1. A01J5WAE03

      Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.039 in.)

      If the distance is less than the minimum, replace the sprocket.

      Tech Tips

      If the worn area is too small or difficult to distinguish from a normal area, perform the steps below.

    2. Wrap the chain around the sprocket.

    3. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      113.8 mm (4.480 in.)

      Tech Tips

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  10. INSPECT CAMSHAFT TIMING GEAR


    1. A01J5YZE03

      Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.039 in.)

      If the distance is less than the minimum, replace the timing gear.

      Tech Tips

      If the worn area is too small or difficult to distinguish from a normal area, perform the steps below.

    2. Wrap the chain around the timing gear.

    3. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      113.8 mm (4.480 in.)

      Tech Tips

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and timing gear.

  11. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A01J6TNE03

      Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.039 in.)

      If the distance is less than the minimum, replace the sprocket.

      Tech Tips

      If the worn area is too small or difficult to distinguish from a normal area, perform the steps below.

    2. Wrap the chain around the drive sprocket.

    3. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      59.4 mm (2.358 in.)

      Tech Tips

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  12. INSPECT CHAIN TENSIONER SLIPPER


    1. A01J6E8E02

      Using a vernier caliper, measure the tensioner slipper wear.

      Maximum wear
      2.0 mm (0.079 in.)

      If the wear is greater than the maximum, replace the tensioner slipper.

  13. INSPECT CHAIN VIBRATION DAMPER


    1. A01J5JAE02

      Using a vernier caliper, measure the vibration damper wear.

      Maximum wear
      2.0 mm (0.079 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  14. INSPECT TIMING CHAIN GUIDE


    1. A01J3UEE02

      Using a vernier caliper, measure the chain guide wear.

      Maximum wear
      0.5 mm (0.020 in.)

      If the wear is greater than the maximum, replace the timing chain guide.

  15. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET


    1. A01J6LBE01

      Wrap the chain around the sprocket.

    2. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      96.7 mm (3.807 in.)

      Tech Tips

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  16. INSPECT BALANCE SHAFT DRIVE GEAR


    1. A01J4RTE01

      Wrap the chain around the sprocket.

    2. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      75.9 mm (2.988 in.)

      Tech Tips

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and sprocket.

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A01J3GME02

      Using a vernier caliper, measure the No. 2 vibration damper wear.

      Maximum wear
      1.0 mm (0.039 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  18. INSPECT NO. 3 CHAIN VIBRATION DAMPER


    1. A01J59PE02

      Using a vernier caliper, measure the No. 3 vibration damper wear.

      Maximum wear
      1.0 mm (0.039 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  19. INSPECT NO. 4 CHAIN VIBRATION DAMPER


    1. A01J4D7E02

      Using a vernier caliper, measure the No. 4 vibration damper wear.

      Maximum wear
      1.0 mm (0.039 in.)

      If the wear is greater than the maximum, replace the vibration damper.

  20. INSPECT CYLINDER HEAD SET BOLT


    1. A01J71VE02

      Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.

      Standard outside diameter
      10.76 to 10.97 mm (0.4236 to 0.4319 in.)
      Minimum outside diameter
      10.40 mm (0.4094 in.)

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.

      If the diameter is less than the minimum, replace the cylinder head bolt.

  21. INSPECT VALVE LASH ADJUSTER

    A01J2ZGE01

    Note


    • Keep the lash adjuster free from foreign matter.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container full of engine oil.

    2. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.

      SST
      09276-75010

    3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed air.

      OK
      Plunger moves up and down.

      Note

      When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

    5. After bleeding air, remove SST. Then, try to quickly and firmly press the plunger with a finger.

      OK
      Plunger is difficult to move.

      If the result is not as specified, replace the lash adjuster.

  22. INSPECT CYLINDER HEAD FOR FLATNESS


    1. A01J52GE01

      Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder block and manifold for warpage.

      Maximum warpage
      0.05 mm (0.0020 in.)

      If the warpage is greater than the maximum, replace the cylinder head.

  23. INSPECT CYLINDER HEAD FOR CRACKS


    1. A01J6SLE01

      Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

      If cracked, replace the cylinder head.

  24. INSPECT INTAKE VALVE SEAT


    1. A01J6XAE01

      Apply a light coat of Prussian blue (or white lead) to the valve face.

    2. Lightly press the valve face against the valve seat.

    3. Check the valve face and valve seat according to the following procedures.


      1. If blue appears 360° around the valve face, the valve face is concentric. If not, replace the valve.

      2. If blue appears 360° around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat.

      3. Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.).

  25. INSPECT EXHAUST VALVE SEAT


    1. A01J6T4E01

      Apply a light coat of Prussian blue (or white lead) to the valve face.

    2. Lightly press the valve face against the valve seat.

    3. Check the valve face and valve seat according to the following procedures.


      1. If blue appears 360° around the valve face, the valve face is concentric. If not, replace the valve.

      2. If blue appears 360° around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat.

      3. Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.).

  26. INSPECT CAMSHAFT THRUST CLEARANCE


    1. A01J6HDE01

      Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

      Standard thrust clearance
      0.10 to 0.24 mm (0.004 to 0.009 in.)
      Maximum thrust clearance
      0.26 mm (0.010 in.)

      If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

  27. INSPECT CAMSHAFT OIL CLEARANCE


    1. A01J4K2E02

      Clean the bearing caps and camshaft journals.

    2. Place the camshafts on the cylinder head.

    3. Lay a strip of Plastigage across each of the camshaft journals.

    4. Install the bearing caps Click here.

      Note

      Do not turn the camshaft.

    5. Remove the bearing caps.

    6. A01J3ALE01

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Item Specified Condition
      No. 1 journal

      0.035 to 0.072 mm

      (0.0014 to 0.0029 in.)
      Other journal

      0.025 to 0.062 mm

      (0.0010 to 0.0028 in.)
      Maximum oil clearance
      0.08 mm (0.0031 in.)

      If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.

    7. Completely remove the Plastigage.

  28. INSPECT COMPRESSION SPRING


    1. A01J7MK

      Using a vernier caliper, measure the free length of the inner compression spring.

      Standard free length
      52.13 mm (2.05 in.)

      If the free length is not as specified, replace the spring.

    2. A01J6KYE02

      Using a steel square, measure the deviation of the inner compression spring at the position shown in the illustration.

      Maximum deviation
      1.3 mm (0.0512 in.)
      Maximum angle (reference)
      2°

      If the deviation is greater than the maximum, replace the spring.

  29. INSPECT INTAKE VALVE


    1. A01J32BE01

      Using a vernier caliper, measure the valve's overall length.

      Standard overall length
      106.26 mm (4.1835 in.)
      Minimum overall length
      105.96 mm (4.1716 in.)

      If the overall length is less than the minimum, replace the valve.

    2. A01J77DE01

      Using a micrometer, measure the diameter of the valve stem.

      Standard valve stem diameter
      5.470 to 5.485 mm (0.2154 to 0.2159 in.)
    3. A01J3M1E01

      Using a vernier caliper, measure the valve head margin thickness.

      Standard margin thickness
      1.05 to 1.45 mm (0.0413 to 0.0571 in.)
      Minimum margin thickness
      0.50 mm (0.0197 in.)

      If the margin thickness is less than the minimum, replace the valve.

  30. INSPECT EXHAUST VALVE


    1. A01J32BE01

      Using a vernier caliper, measure the valve's overall length.

      Standard overall length
      106.74 mm (4.2024 in.)
      Minimum overall length
      106.44 mm (4.1905 in.)

      If the overall length is less than the minimum, replace the valve.

    2. A01J4NJE01

      Using a micrometer, measure the diameter of the valve stem.

      Standard valve stem diameter
      5.465 to 5.480 mm (0.2151 to 0.2157 in.)
    3. A01J66OE01

      Using a vernier caliper, measure the valve head margin thickness.

      Standard margin thickness
      1.2 to 1.6 mm (0.0472 to 0.0630 in.)
      Minimum margin thickness
      0.50 mm (0.0197 in.)

      If the margin thickness is less than the minimum, replace the valve.

  31. INSPECT INTAKE VALVE GUIDE BUSH


    1. A01J6WIE01

      Using a caliper gauge, measure the inside diameter of the guide bush.

      Bush inside diameter
      5.510 to 5.530 mm (0.2169 to 0.2177 in.)

    2. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

      Standard oil clearance
      0.025 to 0.060 mm (0.0010 to 0.0024 in.)
      Maximum oil clearance
      0.08 mm (0.0032 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush.

  32. INSPECT EXHAUST VALVE GUIDE BUSH


    1. A01J7N3E01

      Using a caliper gauge, measure the inside diameter of the guide bush.

      Standard bush inside diameter
      5.510 to 5.530 mm (0.2169 to 0.2177 in.)

    2. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

      Standard oil clearance
      0.030 to 0.065 mm (0.0012 to 0.0026 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush.

  33. INSPECT NO. 1 BALANCE SHAFT


    1. A01J776E01

      Inspect the diameter of the journal.


      1. Using a micrometer, measure the diameter of the balance shaft main journals.

        Standard main journal diameter
        Item Specified Condition
        A 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
        B 37.449 to 37.465 mm (1.4744 to 1.4750 in.)
    2. A01J56PE01

      Inspect the diameter of bearing.


      1. Using a cylinder gauge, measure the inside diameter of the balance shaft bearings.

        Standard bearing inside diameter
        Item Specified Condition
        A 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
        B 37.525 to 37.545 mm (1.4774 to 1.4781 in.)

    3. Inspect the oil clearance.


      1. Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement.

        Standard oil clearance
        Item Specified Condition
        A 0.040 to 0.076 mm (0.0016 to 0.0030 in.)
        B 0.060 to 0.096 mm (0.0024 to 0.0038 in.)
        Maximum oil clearance
        0.15 mm (0.0059 in.)

        If the oil clearance is greater than the maximum, replace the cylinder block and balance shaft.

  34. INSPECT NO. 2 BALANCE SHAFT


    1. A01J7DJE01

      Inspect the diameter of the journal.


      1. Using a micrometer, measure the diameter of the balance shaft main journals.

        Standard main journal diameter
        Item Specified Condition
        A 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
        B 37.449 to 37.465 mm (1.4744 to 1.4750 in.)
    2. A01J6HEE01

      Inspect the diameter of the bearing.


      1. Using a cylinder gauge, measure the inside diameter of the balance shaft bearings.

        Standard bearing inside diameter
        Item Specified Condition
        A 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
        B 37.525 to 37.545 mm (1.4774 to 1.4781 in.)

    3. Inspect the oil clearance.


      1. Subtract the balance shaft main journal diameter measurement from the balance shaft bearing inside diameter measurement.

        Standard oil clearance
        Item Specified Condition
        A 0.040 to 0.076 mm (0.0016 to 0.0030 in.)
        B 0.060 to 0.096 mm (0.0024 to 0.0038 in.)
        Maximum oil clearance
        0.15 mm (0.0059 in.)

        If the oil clearance is greater than the maximum, replace the cylinder block and balance shaft.

  35. INSPECT CYLINDER BLOCK


    1. A01J6LVE01

      Inspect for flatness.


      1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

        Maximum warpage
        0.05 mm (0.0020 in.)

        If the warpage is greater than the maximum, replace the cylinder block.

    2. A01J3A8E01

      Visually check the cylinder for vertical scratches.

      If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

    3. A01J3MGE01

      Inspect the cylinder bore diameter.


      1. Using a cylinder gauge, measure the cylinder bore diameter at position A in the thrust and axial directions.

        Standard diameter
        94.990 to 95.003 mm (3.7398 to 3.7403 in.)

        If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

    4. A01J4YWE04

      Inspect the cylinder ridge.


      1. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

  36. INSPECT PISTON WITH PIN


    1. A01J45YE04

      Inspect the piston oil clearance.


      1. Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.

        Standard distance
        13.8 mm (0.543 in.)
        Standard piston diameter
        Item Specified Condition
        Standard side 94.940 to 94.950 mm (3.7378 to 3.7382 in.)
        O/S 0.50 95.440 to 95.450 mm (3.7575 to 3.7579 in.)

      2. Measure the cylinder bore diameter in the thrust directions.

      3. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

        Standard oil clearance
        0.019 to 0.052 mm (0.0007 to 0.0020 in.)

        If the oil clearance is greater than the standard, replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block.

    2. A01J49PE02

      Inspect the piston pin fit.


      1. At 60°C (140°F), check that the piston pin can be pushed into the piston pin hole with your thumb.

    3. A01J3GNE01

      Inspect the piston pin diameter.

      Tech Tips

      There are 3 piston pin sizes, which are indicated by an A, B or C mark on its surface.


      1. Using a micrometer, measure the piston pin diameter.

        Standard piston pin diameter
        Mark Specified Condition
        A

        21.997 to 22.000 mm

        (0.8660 to 0.8661 in.)
        B

        22.001 to 22.003 mm

        (0.8662 to 0.8663 in.)
        C

        22.004 to 22.006 mm

        (0.8663 to 0.8664 in.)
        D

        22.007 to 22.009 mm

        (0.8664 to 0.8665 in.)

        If the diameter is not as specified, replace the piston pin and piston as a set.

  37. INSPECT PISTON RING SET


    1. A01J51NE01

      Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

      Standard ring groove clearance
      Item Specified Condition
      No. 1 ring 0.020 to 0.075 mm (0.0008 to 0.0030 in.)
      No. 2 ring 0.020 to 0.065 mm (0.0008 to 0.0026 in.)
      Oil ring 0.020 to 0.070 mm (0.0008 to 0.0028 in.)

      If the clearance is not as specified, replace the piston.

    2. A01J7H0E01

      Inspect the piston ring end gap.


      1. Insert the piston ring into the cylinder bore.

      2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.

      3. A01J4MRE01

        Using a feeler gauge, measure the end gap.

        Standard end gap
        Item Specified Condition
        No. 1 ring 0.22 to 0.34 mm (0.0087 to 0.0134 in.)
        No. 2 ring 0.45 to 0.57 mm (0.0177 to 0.0224 in.)
        Oil ring 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
        Maximum end gap
        Item Specified Condition
        No. 1 ring 0.90 mm (0.0354 in.)
        No. 2 ring 1.36 mm (0.0535 in.)
        Oil ring 0.75 mm (0.0295 in.)

        If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

  38. INSPECT CONNECTING ROD


    1. A01J3SLE01

      Using a rod aligner and feeler gauge, check the connecting rod alignment.


      1. Check for bend.

        Maximum bend
        0.03 mm (0.0012 in.) per 100 mm (3.94 in.)

        If the bend is greater than the maximum, replace the connecting rod.

      2. A01J6Q6E01

        Check for twist.

        Maximum twist
        0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

        If the twist is greater than the maximum, replace the connecting rod.

  39. INSPECT PISTON PIN OIL CLEARANCE

    Tech Tips

    There is only 1 type of supply part for piston with pin.


    1. A01J683E02

      Inspect the piston pin oil clearance.

      Tech Tips

      There are 3 connecting rod bush sizes, which are indicated by an A, B or C mark on its surface.


      1. Using a caliper gauge, measure the inside diameter of the connecting rod bush.

        Standard bush inside diameter
        Mark Specified Condition
        A 22.005 to 22.008 mm (0.86633 to 0.86645 in.)
        B 22.008 to 22.011 mm (0.86645 to 0.86657 in.)
        C 22.011 to 22.014 mm (0.86657 to 0.86669 in.)

      2. Subtract the piston pin diameter measurement from the bush inside diameter measurement.

        Standard oil clearance
        0.001 to 0.007 mm (0.00004 to 0.00028 in.)
        Maximum oil clearance
        0.01 mm (0.00039 in.)

        If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.

  40. INSPECT CONNECTING ROD BOLT


    1. A01J342E03

      Using a vernier caliper, measure the tension portion diameter of the bolt.

      Standard diameter
      7.2 to 7.3 mm (0.283 to 0.287 in.)
      Minimum diameter
      7.0 mm (0.276 in.)

      If the diameter is less than the minimum, replace the bolt.

  41. INSPECT CRANKSHAFT


    1. A01J7LSE01

      Inspect for circle runout.


      1. Place the crankshaft on V-blocks.

      2. Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.03 mm (0.0012 in.)

        If the circle runout is greater than the maximum, replace the crankshaft.

    2. A01J4VJE01

      Inspect the main journals.


      1. Using a micrometer, measure the diameter of each main journal.

        Standard journal diameter
        Item Specified Condition
        No. 3 journal 59.981 to 59.994 mm (2.3615 to 2.3620 in.)
        Except No. 3 journal 59.987 to 60.000 mm (2.3229 to 2.3622 in.)

        If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

      2. Check each main journal for taper and out-of-round as shown in the illustration.

        Maximum taper and out-of-round
        0.005 mm (0.0002 in.)

        If the taper and out-of-round is greater than the maximum, replace the crankshaft.

    3. A01J3D0E01

      Inspect the crank pin.


      1. Using a micrometer, measure the diameter of each crank pin.

        Diameter
        52.989 to 53.002 mm (2.0862 to 2.0867 in.)

        If the diameter is not as specified, check the oil clearance (see "INSPECT CONNECTING ROD OIL CLEARANCE" procedures). If necessary, replace the crankshaft.

      2. Check each crank pin for taper and out-of-round as shown in the illustration.

        Maximum taper and out-of-round
        0.003 mm (0.0001 in.)

        If the taper and out-of-round is greater than the maximum, replace the crankshaft.

  42. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A01J71VE03

      Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.

      Standard outside diameter
      10.76 to 10.97 mm (0.4236 to 0.4319 in.)
      Minimum outside diameter
      10.66 mm (0.4197 in.)

      If the diameter is less than the minimum, replace the crankshaft bearing cap bolt.