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1.Remove oil from the
crankshaft journal and crankshaft bearing inner
surface.
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2.Install the
crankshaft.
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![](../../../img/11/AK503753AB00ENG.png)
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3.Cut plastigage to the same
length as the width of the bearing and place it on the
journal
in parallel with its axis.
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![](../../../img/11/AK503754AA00ENG.png)
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4.Install the crankshaft
bearing cap carefully and tighten the bolts to the specified
torque of 74 ± 4 N·m. 5.Carefully
remove the crankshaft bearing cap. 6.Measure the
width of the smashed plastigage at its widest section by
using a scale
printed on the plastigage bag. Standard
value:
<No.1,No.4> 0.012 -
0.030 mm <No.2,No.3> 0.018 - 0.036
mm Limit: 0.1 mm
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1.Check the oil seal lip for
wear and damage.
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2.Check the rubber for
deterioration or hardening.
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3.Check the oil seal case
for cracks and damage.
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1.Visually check for
scratches, rust, and corrosion. Use also a flaw detecting
agent
for the check. If defects are evident, correct, or
replace.
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![](../../../img/11/AK400448AA00ENG.png)
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2.Using a straightedge and
feeler gauge, check the block top surface for warpage. Make
sure that the surface is free from gasket chips and other
foreign matter. Standard value: 0.05
mm Limit: 0.1 mm 3.If the distortion is
excessive, correct within the allowable limit or
replace. Grinding limit: *0.2
mm *Includes/combined with cylinder head
grinding.
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![](../../../img/11/AK400449AD00ENG.png)
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4.Check the cylinder walls
for scratches and seizure. If defects are evident, correct
(bored to an oversize) or replace. 5.Using a
cylinder gauge, measure the cylinder bore and
cylindricality. If worn badly,
correct by boring the cylinders to an oversize and replace
pistons and piston rings. Measure
at the points shown in the
illustration. Standard
value
Cylinder Inside Diameter: 95.0
mm Cylindricality: 0.01 mm
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![](../../../img/11/AK503752AB00ENG.png)
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1.Oversize pistons to be
used should be determined on the basis of the largest bore
cylinder.
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Piston size
identification
Size
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Identification
mark
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0.25 mm Oversize
diameter
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0.25
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0.50 mm Oversize
diameter
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0.50
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note |
Size mark is stamped on the
piston top.
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2.Measure the outside diameter of the piston
to be used. Measure it in the thrust direction
as shown. 3.Based on the measured piston Outside
Diameter (OD), calculate the boring finish
dimension. Boring finish dimension =
Piston OD + (clearance between piston
OD and cylinder) - 0.02 mm (honing
margin) 4.
caution |
To prevent distortion that may
result from temperature
rise during honing, bore cylinders in the order
of number 2, number 4, number 6, number 1,
number
3 and number 5.
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Bore all cylinders to the calculated boring finish
dimension. 5.Hone to the final finish dimension
(piston OD + clearance between piston
OD and cylinder). Standard
value
Cylinder Inside Diameter: 95.0
mm Cylindricality: 0.01
mm
6.Check the clearance between
the piston and cylinder. Clearance between
piston and cylinder: 0.02 - 0.04
mm
note |
When boring cylinders, finish
all six cylinders to the same oversize. Do not
bore only
one cylinder to an oversize.
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