13576201

Check the end play between piston and connecting rod.

End play

Standard : 0.05 ~ 0.302 mm (0.0020 ~ 0.0119 in)

If out-of-tolerance, install a new connecting rod.

If still out-of-tolerance, replace the crankshaft.

Check the connecting rod bearing oil clearance.

(1)

Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.

(2)

Remove the 2 connecting rod cap bolts.

(3)

Remove the connecting rod cap and lower bearing.

(4)

Clean the crankshaft pin journal and bearing.

(5)

Place a plastigage across the crankshaft pin journal.

(6)

Reinstall the lower bearing and cap, and tighten the nuts.

Tightening torque :

10.7 ~ 14.7 N.m (1.1 ~ 1.5 kgf.m, 8.0 ~ 10.8 lb-ft) + (88 ~ 92°)

note

●

Do not turn the crankshaft.

●

Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.

(7)

Remove the 2bolts, connecting rod cap and lower bearing .

(8)

Measure the plastigage at its widest point.

Standard oil clearance

0.025 ~ 0.043 mm (0.0010 ~ 0.0017 in)

(9)

If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.

Recheck the oil clearance.

note

Do not file, shim, of scrape the bearings or the caps to adjust clearance.

(10)

If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.

Recheck the oil clearance.

note

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

note

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting Rod Mark Location

Discrimination Of Connecting Rod

Mark	Connecting rod big-end inner diameter
A	49.000 ~ 49.006 mm (1.9291 ~ 1.9294 in)
B	49.006 ~ 49.012 mm (1.9294 ~ 1.9296 in)
C	49.012 ~ 49.018 mm (1.9296 ~ 1.9298 in)

Crankshaft Pin Journal Mark Location

Discrimination Of Crankshaft Pin Journal

Mark	Crankshaft pin journal outer diameter
A	46.009 ~ 46.015 mm (1.8114 ~ 1.8116 in)
B	46.003 ~ 46.009 mm (1.8111 ~ 1.8114 in)
C	45.997 ~ 46.003 mm (1.8109 ~ 1.8111 in)

Connecting Rod Bearing Mark Location

Discrimination Of Connecting Rod Bearing

Color	Connecting rod bearing thickness
Blue	1.477 ~ 1.480 mm (0.0581 ~ 0.0583 in)
Black	1.480 ~ 1.483 mm (0.0583 ~ 0.0584 in)
None	1.483 ~ 1.486 mm (0.0584 ~ 0.0585 in)
Green	1.486 ~ 1.489 mm (0.0585 ~ 0.0586 in)
Yellow	1.489 ~ 1.492 mm (0.0586 ~ 0.0587 in)

(11)

Select the bearing by using selection table.

Connecting Rod Bearing Selection Table

Connecting rod bearing		Connecting rod mark
Connecting rod bearing		A	B	C
Crank shaft pin journal mark	A	Blue	Black	None
	B	Black	None	Green
	C	None	Green	Yellow

Check the connecting rods.

(1)

When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.

(2)

Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.

(3)

Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.

Allowable bend of connecting rod :

0.05mm / 100 mm (0.0020in / 3.94in ) or less

Allowable twist of connecting rod :

0.1mm / 100 mm (0.0039in / 3.94 in) or less

Clean the piston.

(1)

Using a gasket scraper, remove the carbon from the piston top.

(2)

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3)

Using solvent and a brush, thoroughly clean the piston.

note

Do not use a wire brush.

Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.

Piston-to-cylinder clearance :

0.060 ~ 0.080 mm (0.0024 ~ 0.0031 in)

(1)

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

Cylinder bore diameter :

77.200 ~ 77.230 mm (3.0394 ~ 3.0405 in)

(2)

Measure the piston outside diameter at 10 mm (0.39 in) from bottom land of the piston.

Piston outside diameter :

77.130 ~ 77.160 mm (3.0366 ~ 3.0377 in)

Select the piston matching with cylinder bore class.

Piston-to-cylinder clearance :

0.060 ~ 0.080 mm (0.0024 ~ 0.0031 in)

(1)

Check the cylinder bore size code on the cylinder block front face.

Discrimination Of Cylinder Bore Size

Mark	Cylinder bore inner diameter
A	77.200 ~ 77.210 mm (3.0394 ~ 3.0398 in)
B	77.210 ~ 77.220 mm (3.0398 ~ 3.0402 in)
C	77.220 ~ 77.230 mm (3.0402 ~ 3.0405 in)

(2)

Check the piston size mark (A) on the piston top face.

Discrimination Of Piston Outer Diameter

Mark	Piston outer diameter
A	77.130 ~ 77.140 mm (3.0366 ~ 3.0370 in)
B	77.140 ~ 77.150 mm (3.0370 ~ 3.0374 in)
C	77.150 ~ 77.160 mm (3.0374 ~ 3.0378 in)

Inspect the piston ring side clearance.

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

Piston ring side clearance

No.1 : 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in)

No.2 : 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in)

Oil ring : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

If the clearance is greater than maximum, replace the piston.

Inspect the piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is over the service limit, the cylinder block must be replaced.

Piston ring end gap

No.1 : 0.20 ~ 0.30 mm (0.0079 ~ 0.0118 in)

No.2 : 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in)

Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157 in)

Measure the outer diameter of piston pin.

Piston pin diameter :

27.995 ~ 28.000 mm (1.1022 ~ 1.1024 in)

Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :

0.004 ~ 0.015 mm (0.0002 ~ 0.0006 in)

Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.

Piston pin-to-connecting rod interference :

0.022 ~ 0.039 mm (0.0009 ~ 0.0015 in)