Inspection

ENGINE UNIT

INSPECTION
1. INSPECT BALANCE SHAFT THRUST CLEARANCE
(a) Install the balance shafts.

(b) Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 inch)
Maximum thrust clearance: 0.09 mm (0.0035 inch)
If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.

2. INSPECT BALANCE SHAFT OIL CLEARANCE
(a) Clean each bearing and journal.
(b) Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
(c) Place the No. 1 and No. 2 balance shafts onto the crankcase.

(d) Lay a strip of Plastigage across each journal.
(e) Install the balance shaft housing.

NOTICE: Do not turn the balance shafts.

(f) Remove the balance shafts.

(g) Measure the Plastigage at its widest point.
Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 inch)
Maximum oil clearance: 0.049 mm (0.0019 inch)

NOTICE: Remove the Plastigage completely after the measurement.

If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft.
(h) If replacing a bearing, select a new one with the same number.

Standard balanceshaft housing journal bore diameter:

Standard bearing center wall thickness:

Standard balanceshaft journal diameter:

(i) Inspect the balance shaft housing bolts.
(1) Using vernier calipers, measure the length of the bolts from the seat to the end.
Standard bolt length: 58.3 to 59.7 mm (2.295 to 2.350 inch)
Maximum bolt length: 60.3 mm (2.374 inch)
If the bolt length is greater than the maximum, replace the balance shaft housing bolt.

3. INSPECT CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbs.) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation: 114.5 mm (4.508 inch)

NOTICE: Perform the measurement at 3 random places. Use the average of the measurements.

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

4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbs.) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation: 102.2 mm (4.024 inch)

NOTICE: Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the No. 2 chain.

5. INSPECT OIL PUMP DRIVE GEAR
(a) place the chain around the gear.
(b) Using vernier calipers, measure the diameter of the gear and chain.
Minimum gear diameter (with chain): 48.2 mm (1.898 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

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

6. INSPECT OIL PUMP DRIVE SHAFT GEAR
(a) Place the chain around the gear.
(b) Using vernier calipers, measure the diameter of the gear and chain.
Minimum gear diameter (with chain): 48.2 mm (1.898 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

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

7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Place the chain around the timing gear.
(b) Using vernier calipers, measure the diameter the timing gear and chain.
Minimum gear diameter (with chain): 97.3 mm (3.831 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

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

8. INSPECT CAMSHAFT TIMING SPROCKET
(a) Place the chain around the sprocket.
(b) Using vernier calipers, measure the diameter of the sprocket and chain.
Minimum sprocket diameter (with chain): 97.3 mm (3.831 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

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

9. INSPECT CRANKSHAFT TIMING GEAR
(a) Place the chain around the timing gear.
(b) Using vernier calipers, measure the diameter of the timing gear and chain.
Minimum gear diameter (with chain): 51.6 mm (2.031 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing gear.

10. INSPECT CHAIN TENSIONER SLIPPER
(a) Using vernier calipers, measure the tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the chain tensioner slipper.

11. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Using vernier calipers, measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the No. 1 chain vibration damper.

12. INSPECT CHAIN TENSIONER PLATE
(a) Using vernier calipers, measure the vibration damper wear.
Maximum wear: 0.5 mm (0.020 inch)
If the wear is greater than the maximum, replace the chain tensioner plate.

13. INSPECT NO. 1 CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
(b) Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.

14. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Install the connecting rod cap.

(b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.

15. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Clean the crank pin and bearing.
(b) Check the crank pin and bearing for pitting and scratches.

(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Install the connecting rod cap.

NOTICE: Do not turn the crankshaft.

(f) Remove the 2 bolts and connecting rod cap.

(g) Measure the Plastigage at its widest point.
Standard oil clearance: 0.032 to 0.063 mm (0.0013 to 0.0025 inch)
Maximum oil clearance: 0.063 mm (0.0025 inch)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

NOTICE: Completely remove the Plastigage after the measurement.

HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, or 3 mark on its surface.

Standard connecting rod large end bore diameter:

Standard connecting rod bearing thickness:

Standard crankshaft pin diameter:

16. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.

17. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both thrust and axial directions.
Standard diameter: 88.500 to 88.513 mm (3.4843 to 3.4847 inch)
Maximum diameter: 88.633 mm (3.4894 inch)
If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.

18. INSPECT PISTON
(a) Using a gasket scraper, remove the carbon from the piston top.

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

(d) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 44.3 mm (1.7441 inch) from the piston head.
Standard piston diameter: 88.469 to 88.479 mm (3.4830 to 3.4834 inch)
If the diameter is not as specified, replace the piston.

19. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.021 to 0.044 mm (0.0008 to 0.0017 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)
If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

20. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Standard ring groove clearance:

21. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.

(b) Using a feeler gauge, measure the end gap.

Standard end gap:

Maximum end gap:

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, replace the cylinder block.

22. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the piston pin bore diameter.
Standard piston pin bore diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 inch)

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

(b) Using a micrometer, measure the piston pin diameter.
Standard piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)

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

(c) Using a caliper gauge, measure the connecting rod small end bore diameter.
Standard connecting rod small end bore diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)

If the diameter is not as specified, replace the connecting rod.

(d) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.0004 to 0.0003 inch)
Maximum oil clearance: 0.010 mm (0.0004 inch)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
(e) Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.011 mm (0.0004 inch)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.

23. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)
If the diameter is less than the minimum, replace the connecting rod bolt.

24. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the misalignment is greater than the maximum, replace the connecting rod.

(2) Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than the maximum, replace the connecting rod.

25. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the taper and distortion are greater than the maximum, replace the crankshaft.

(b) Using a micrometer, measure the diameter of each main journal.
Standard diameter: 54.988 to 55.000 mm (2.1649 to 2.1654 inch)
If the diameter is not as specified, check the crankshaft oil clearance.
(c) Check each main journal for taper and distortion as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 inch)
If the taper and distortion are greater than the maximum, replace the crankshaft.

Standard diameter (Reference):

(d) Using a micrometer, measure the diameter of each crank pin.
Standard diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 inch)
If the diameter is not as specified, check the connecting rod oil clearance.
(e) Inspect each crank pin for taper and distortion as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 inch)
If the taper and distortion are greater than the maximum, replace the crankshaft.

26. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Install the main bearing cap.

(b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0095 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 inch).

27. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Check the crank journal and bearing for pitting and scratches.
(b) Install the crankshaft bearing.
(c) Place the crankshaft on the cylinder block.

(d) Lay a strip of Plastigage across each journal.
(e) Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT: A number is marked on each main bearing cap to indicate the installation position.

(f) Install the main bearing cap.

NOTICE: Do not turn the crankshaft.

(g) Remove the main bearing caps.

(h) Measure the Plastigage at its widest point.
Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 inch)
Maximum oil clearance: 0.060 mm (0.0024 inch)
If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

NOTICE: Remove the Plastigage completely after the measurement.

HINT:
^ If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number according to the chart below. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
^ EXAMPLE: Cylinder block "3" + Crankshaft "5"= Total number 8 (Use bearing "3")

Standard cylinder block journal bore diameter:

Standard crankshaft journal diameter (Part 1):

Standard crankshaft journal diameter (Part 2):

Standard bearing center wall thickness:

28. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 inch)
Minimum diameter: 7.2 mm (0.284 inch)
If the diameter is less than the minimum, replace the bolt.