[11F] ENGINE OVERHAUL <4G69> - - CRANKSHAFT AND CYLINDER BLOCK - INSPECTION | PRINT PAGE / INDEX / PRIOR / NEXT

INSPECTION
| CRANKSHAFT JOURNAL OIL CLEARANCE <PLASTIC GAUGING MATERIAL METHOD> Remove oil from the crankshaft journal and crankshaft bearing. Install the crankshaft.
| Cut the plastic gauging material to the same length as the width of bearing and place it on journal in parallel with its axis. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. Carefully remove the crankshaft bearing cap.
| Measure the width of the plastic gauging material at its widest part by using a scale printed on the plastic gauging material package. Standard value: 0.02 - 0.04 mm Limit: 0.1 mm
| CYLINDER BLOCK
| Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct or replace. 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 If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: 0.2 mm *Includes/combined with cylinder head grinding Cylinder block height (when new): 290 mm Check cylinder walls for scratches and seizure. If defects are evident, replace or bore to oversize and replace pistons and piston rings.
| Using a cylinder gauge, measure the cylinder bore and cylindrically. If worn badly, correct the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in the illustration. Standard value: Cylinder inner diameter 87.0 mm Cylindrically 0.01 mm or less
| BORING CYLINDER
| Oversize pistons to be used should be determined on the basis of the largest bore cylinder.
Piston size identification
Size | Identification mark
--- | ---
0.50 mm oversize diameter | 50
| NOTE: Size mark is stamped on the piston top. Measure the outside diameter (OD) of the piston to be used. Measure it in thrust direction as shown. Based on the measured piston OD, calculate the boring finish dimension. Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) -0.02 mm (honing margin) CAUTION To prevent distortion that may result from temperature rise during honing, bore cylinders, working from number 2 to number 4 to number 1 to number 3. Bore all cylinders to the calculated boring finish dimension. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder). Check the clearance between the piston and cylinder. Clearance between piston and cylinder: 0.02 - 0.04 mm NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.

[11F] ENGINE OVERHAUL <4G69> - - CRANKSHAFT AND CYLINDER BLOCK - INSPECTION | PRINT PAGE / INDEX / PRIOR / NEXT

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