CYLINDER BLOCK

< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]

CYLINDER BLOCK
Exploded View INFOID:0000000010282024

E1BIA1216GB

1. Centring dowe 2. Cylinder block 3. TDC hole plug

4. Scraper ring 5. Sealing ring 6. Compression ring
7. Gudgeon pin locking spring ring 8. Piston 9. Con rod

EM-446
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
10. Piston pin 11. Con rod bearing shell 12. Con rod bolt
13. crankshaft thrust washer 14. Flywheel bolts (M/T Models) 15. Flywheel (M/T Models) A
16. Crankshaft seal on gearbox end bolt 17. Crankshaft seal on gearbox end 18. Crankshaft bearing shell
19. Crankshaft bearing cap 20. Crankshaft bearing cap bolt 21. Crankshaft
22. Timing sprocket 23. Oil pan upper 24. Oil pan upper bolts EM
25. Drive plate (CVT Models) 26. Pilot bushing
A. Refer to EM-447 B. Refer to EM-447 C. Refer to EM-447
D. Refer to EM-447 C

Refer to GI-4, "Components" for symbols shown in the figure.

Disassembly and Assembly INFOID:0000000010282025
D

Disassembly
E
1. Remove oil level sensor.
CAUTION:
Handle it carefully and avoid impacts.
2. Remove crankshaft position sensor. F
CAUTION:
• Handle it carefully and avoid impacts.
• Never place sensor in a location where it is exposed to magnetism. G
3. Remove rear oil seal retainer.
4. Remove pilot bushing using the pilot bushing puller (commercial service tool), if necessary.
5. Remove oil pan (upper). Refer to EM-437, "Exploded View". H
6. Remove oil pump related parts. Refer to EM-412, "Exploded View".
7. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to I
EM-459, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap. J
• Put a paint mark on cap to identify each cylinder.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side. K

PBIC0259E
N
CAUTION:
• Be careful not to damage oil jets (A), cylinder wall and
crankshaft pin, resulting from an interference of the con- O
necting rod big end.
• Never disassemble oil jets.
P

JPBIA1817ZZ

EM-447
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
8. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct.
9. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-459, "Inspection".
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
them excessively.

JPBIA0194ZZ

10. Remove the snap rings (1) using a screwdriver (A), and then
release the piston pin.

B : Channel

JPBIA0639ZZ

11. Remove main bearing cap mounting bolts with the following procedure:
• Measure crankshaft end play before loosening main bearing cap mounting bolts. Refer to EM-459,
"Inspection".
a. NOTE:
Always mark the position of each crankshaft bearing shell using
an indelible marker pen, in relation to the crankshaft bearing
number
Remove:
• the crankshaft bearing cap bolts,
• the crankshaft bearing caps,
• the crankshaft,
• the cranshaft bearing shells.

E1BIA0530ZZ

NOTE:
Always mark the position of each crankshaft bearing shell using an
indelible marker pen, in relation to the crankshaft bearing number
12. Remove the crankshaft thrust washer (1)

E1BIA0531ZZ

EM-448
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
13.
Remove piston base cooling jets (1) following this procedure: A
CAUTION:
Wear goggles with side protectors for this operation.
EM

E1BIA0555ZZ

D
a.
• Drill the piston base coolibg jets using a [7 mm (0.3in)] diame-
ter drill bit. E
NOTE:
Do not take out the ball from the piston base cooling nozzle, oth-
erwise swarf may enter the lubrification circuit
• Remove the spring tappet (1) and the springs (2) without tak- F
ing out the ball (3).
• Remove any swarf present with a brush with non abrasive
bristles and a compressed air nozzle. G
E1BIA0556ZZ

b. H
• Screw the tool [SST: Mot. 1485-01] (1) into the drilled piston
base cooling jets using a [6 mm (0.2 in)] Allen key, which
slides into the tool [SST: Mot. 1485-01].
I

E1BIA0557ZZ K

c.
• Screw the tool [SST: Emb. 880] (1) on the tool [SST: Mot. L
1485-01].
• Remove the piston base cooling jets.
• Fit a blanking plug whenever a piston base cooling jet is
removed. M

E1BIA0558ZZ

Assembly O
1. Fully air-blow engine coolant and engine oil passages in the cylinder block, cylinder bore and crankcase
to remove any foreign matter.
CAUTION: P
Use a goggles to protect your eye.
2. Install the new piston base cooling jet following procedure:
a. Remove the blanking plugs.
b. Use pressurised air and clean cloths to clean the oil circuit, the cylinders and the joint faces to ensure
there is no swarf present.

EM-449
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
c.Description of the tool [SST: Mot. 1972]

E1BIA0559ZZ

The tool [SST: Mot. 1972] consists of :

• a plate (1),
• a plate bolt (2),
• a pushrod (3),
• an end piece (4),
• a system nut-screw (5).

d.
• Fit the plate (1) of the tool [SST: Mot. 1972] on the cylinder
block without tihten the bolts (2)

E1BIA0560ZZ

e.
• Fit the piece of the tool [SST: Mot. 1972] in the push-rod of the
tool [SST: Mot. 1972].
• Place the "end piece - pushrod" (1) assembly of the tool [SST:
Mot. 1972] in the plate to centre the plate above the opening of
the piston base cooling jet.
• Tighten the plate bolts.
• Remove the "end piece - pushrod" assembly from the plate.

E1BIA0561ZZ

f.
• Insert the piston base cooling jet in the pushrod.
• Place the "pushrod - piston base cooling jet" assembly in the
plate by presenting the jet in front of its opening.
• Fit the system nut-screw (1) on the plate.
• Tighten the bolt (2) to has retaining wall of the pushrod on the
plate.
• Remove the tool [SST: Mot. 1972].

E1BIA0562ZZ

3. Install main bearings and thrust bearings with the following procedure:
EM-450
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
a. Remove dust, dirt, and engine oil from the bearing mating surfaces of the cylinder block and main bearing
cap. A
b. Centre the grooved bearing shell on bearing No.1 of the cylinder block while aligning the groove of the
bearing shell with the hole of the bearing.
• Secure the flush bearing shell and push from the opposite side EM
the position of the bearing shell flush with the bearing.

E1BIA0532ZZ E

c.
F

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d. I

E1BIA0534GB

EM-451
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
e. Measure the distance (X1) between the bearing face (1) and the edge of the bearing shell at points (A),
(B) and (C) using a depth gauge.
f. If necessary, adjust the position of the bearing shell to the value (X1) = [179 mm (7.0 in)].
g. Repet the previous operations for the bearing shells of the bearings No 2, 4 and 5.
h. If necessary, adjust the position of the bearing shells:
- of bearings No. 2 and 4 to the value (X2) = [88 mm (3.5 in)].
- of the bearing No. 5 to the value (X1) = [176 mm (6.9 in)].
i.
Place:
• a rectified shim (1) against the mating face of the crankshaft
thrust washer on bearing No.3
• the grooved bearing shell against the rectified shim.

E1BIA0535ZZ

• Secure the flush bearing shell against the rectified shimat (2) and push from the opposite side to posi-
tion the bearing shell flush with the bearing..
j.
• Mesure the distance (X3) between the bearing face of the
thrust washer and the bearing shell edge using a depth gauge.

E1BIA0536GB
k.
• Centre the grooved bearing shell on the bearing, aligning the
shell with the hole groove.
• Adjust the position of the bearing shell at points (A), (B) and
(C) using the rectified shim (1) and a set of feeler gauges
(thickness of the shim (2) = (X3) : [2 mm (0.1 in)].

E1BIA0537ZZ

l.
Place:
• the bearing cap on a bench,
• a non-grooved bearing shell against the bench.

• Secure the flush bearing shell with the bearing cap at (1) and
push from the opposite side to bring the bearing shell flush
with the bearing cap.

E1BIA0538ZZ

EM-452
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
m.
• Measure the distance (X4) between the edge of the bearing A
shell and the wall of the bearing cap at points (A), (B) and (C)
using a depth gauge.
EM

E1BIA0539GB

D
n.
• Adjust the position of the bearing shell at point (A), (B) and
using a set of feeler gauges (feeler gauges (thichness of the
E
shim (1) = X4 : [2 mm (0.1 in)]
• Repeat the previous operations for the other bearing caps.

G
E1BIA0540ZZ

o.
H
• Position the crankshaft thrust washers on the cylinder block
(washer plug (1) in the cylinder block notch)
• Use engine oil to lubricate the crankshaft journal bearing
shells and thrust washers (only the face making contact with I
the crankshaft).
NOTE:
Ensure the bearing shells and the thrust washers do not move J
when refitting the crankshaft and bearing caps.

E1BIA0541ZZ
K
4. Install crankshaft, the bearing caps and the crankshaft bearing bolts.
NOTE:
Check that the bearing caps are in contact with the cylinder block before tightening the bearing cap bolts. L
5. Install main bearing caps with the following procedure:
a. Align the identification number to the journal position to install as
shown in the figure. M

: Engine front
N

JPBIA0786ZZ
P

EM-453
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
b. Tighten new main bearing cap bolts in numerical order as shown
in the figure with the following procedure:

: Engine front

i. Pretighten main bearing cap bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

Tighten main bearing cap bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb) JPBIA1801ZZ

CAUTION:
Be sure to check that the main bearing cap is in contact with the cylinder block before tightening
the bolts.
ii. Turn bolts 110 degrees clockwise (angle tightening).
CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100 ( — )] (A) or protractor. Never judge by
visual inspection without the tool.

JPBIA0846ZZ

• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-459, "Inspection".
• If replacing the crankshaft, always identify the piston height category to refit in each cylinder to garantee that
the piston protusion in relation to the cylinder block remains within the tolerance, before refitting the con rod
- piston assemblies. Refer to EM-459, "Inspection".

6. Install piston to connecting rod with the following procedure:

a. Install snap ring to the groove of the piston rear side.
• Insert it fully into the groove.
b. Assemble piston to connecting rod.
• Point the mark engraved (A) on the piston head facing and the
bosses (B) of the big end as shown in the figure.

: Engine front

• Piston pin can be pushed in by hand without excessive force.

From the front to the rear, insert piston pin into piston and con-
necting rod.

JPBIA0732ZZ

c. Install snap ring to the groove of the piston front side.

• Insert it fully into the groove.
• After installing, check that connecting rod moves smoothly.
7. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.

EM-454
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
• Position each ring with the gap as shown in the figure referring
to the piston front mark. A

EM

JPBIA1058ZZ

D
8.
• Fit the scraper ring (1) with the hand by way of the con rod.
E

G
E1BIA0503ZZ

9.
H
• Lubricate piston pin with engine oil.
• Position the con rod in relation to the piston (piston marking (1)
"V" is opposite the machined bosses (2) on the big end)
I
NOTE:
Piston marking V engine flywheel end, Con rod marking
(machined bosses) timing end. J

E1BIA0504ZZ
K
10. Engage the pin in the piston and in the samll end.
NOTE:
Check that the piston pin slides and rotates easily in the piston and the small end. L
11.
• Refit the locking spring ring to the piston pin using a flat screw-
driver (apply pressure in the groove (1)). M
NOTE:
Position the opening in the locking spring ring towards the piston
crown.
N

O
E1BIA0505ZZ

EM-455
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
12.
Place:
• the con rod body on the bench,
• the con rod upper bearing shell (width = [18.2 mm (0.7 in)]

• Secure the flush bearing shell of the con rod body mating face
on side (1) and push from the opposite side until the con rod
body mating face is flush.

Place: E1BIA0506ZZ
• the con rod cap on the bench,
• the con rod lower bearing shell (width = [18.2 mm (0.7 in)]

• Secure the flush bearing shell of the con rod cap mating face on side (2) and push from the opposite
side until the con rod cap mating face is flush.

13.
• Mesure the distance (X) between the edge of the bearing shell
and the wall of the con rod body at points (A), (B) and (C).

E1BIA0507GB

14.
• Centre the bearing shell on the con rod body.
• Adjust the position of the bearing shell at points (A), (B) and
(C) using a set of feeler gauges = X: [2 mm (0.1 in)].
• Repeat the previous operations on the remaining con rod bod-
ies and caps

E1BIA0508ZZ

Lubricate with engine oils:

• the cylinder block barrels,
• the piston rings
• the piston skirts,
• the crankshaft crankpins

• Orient the piston rings on the piston pin axis.

15. Lubricate the tool [SST: Mot.1979].

EM-456
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
16.
• Check that the piston rings are correctly engaged in the piston A
grooves
• Put the piston on a plane and clean surface.
• Verify the absence of over lap (1) of the tips of the scraper
EM
ring.
NOTE:
Manipulate the piston exclusively by the skirt or the con rod,
without touching the scraper ring. C

E1BIA0509ZZ

D
17.
• Insert the tool [SST: Mot.1979] (1) on the piston, conical part
the first one, by the con rod.
E
NOTE:
The engagement of the tool [SST: Mot.1979] on the piston has
to be made without forcing. If resistance during the engagement
occures, put off the tool and to re-engage it. F

G
E1BIA0510ZZ

18.
H
• Check that the pistons correspond to the cylinder block barrels
(No. 1 timing end)
• Place the "con rod - piston - tool" (1) assembly in the cylinder.
NOTE: I
Position the point of the "V" engaged on the piston towards the
flywheel end.
J

E1BIA0511ZZ
K
19. WARNING:
Failure to observe the following procedure may result in destruction of the engine.
• Gradually insert the "con rod - piston" assembly in the cylinder ( avoid any contact between the con rod L
and the piston base cooling jet) using only of the hand.
• Position the big end on the crankshaft crankpin.
• Refit the con rod cap, ensuring that the con rod caps and bodies correspond. Refer to EM-459, "Inspec- M
tion".

20.
N
a. Tighten new connecting rod cap bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb) O

EM-457
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
b. Turn bolts 110 degrees clockwise (angle tightening).
CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100 ( — )] (A) or protractor. Never judge by
visual inspection without the tool.

JPBIA0846ZZ

• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-459, "Inspection".
• Check the piston protrusion. Refer to EM-459, "Inspection".
21. Install oil pump and related parts.
22. Install oil pan (upper). Refer to EM-437, "Exploded View".
23. Install rear oil seal retainer with the following procedure:
a. Set guide bolt (A) and protector (B) to rear oil seal retainer (1).
NOTE:
The protector is supplied in the new oil seal parts kit.
b. Move the rear oil seal retainer evenly by hand until it makes con-
tact with the cylinder block.

JPBIA0777ZZ

c. Tighten mounting bolts in two steps separately in numerical

order as shown in the figure.
i. Tighten mounting bolts No.1 and 5.

: 5.0 N·m (0.51 kg-m, 44 in-lb)

ii. Tighten mounting bolts No. 1 to 8 in numerical order as shown.

: 12.0 N·m (1.2 kg-m, 106 in-lb)

JPBIA0645ZZ

24. Install pilot bushing.

• Using the drift, force fit the pilot bushing until its front end contacts crankshaft.
25. Install flywheel by aligning the mark (1).
NOTE:
The openings of the flywheel bolts must be aligned.
a. Install bolts without tightening them.
b. Fix flywheel using flywheel locking tool [SST: — (Mot.1431)].

E1BIA0773ZZ

EM-458
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
c. Tighten bolts in numerical order as shown in the figure with the
following procedure: A
i. Tighten mounting bolts.

EM
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
ii. Turn 50 degrees clockwise (angle tightening).
C

JPBIA0812ZZ

26. Install drive plate.

a. Install bolts without tightening them. E
b. Fix drive plate using flywheel locking tool [SST: — (Mot.1431)].
c. Tighten bolts in numerical order as shown in the figure with the
following procedure: F
i. Tighten mounting bolts.

: 50.0 N·m (5.1 kg-m, 37 ft-lb) G

E1BIA1163GB

I
27. Assemble in the reverse order of disassembly.
Inspection INFOID:0000000010282026

J
CRANKSHAFT END PLAY
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial K
indicator (A).

Standard : Refer to EM-475, "Cylinder Block". L

• If it exceeds the standard, replace thrust bearings, and measure
again. If it still exceeds the standard, also replace crankshaft.
M

JPBIA0845ZZ

N
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
O
Standard : Refer to EM-475, "Cylinder Block".
• If it exceeds the standard, measure the connecting rod bearing oil
clearance. Refer to “CONNECTING ROD BEARING OIL CLEAR- P
ANCE”.

JPBIA0228ZZ

CRANKSHAFT MAIN JOURNAL DIAMETER

EM-459
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
• Measure the outer diameter of crankshaft main journals with a micrometer.

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, measure the main bearing oil clearance. Refer to “MAIN BEARING OIL CLEAR-
ANCE”.
CONNECTING ROD SIDE CLEARANCE
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, replace connecting rod, and measure
again. If it still exceeds the standard, also replace crankshaft.

JPBIA0847ZZ

CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap without connecting rod bearing installed,
and tightening connecting rod cap bolts to the specified torque.
Refer to EM-447, "Disassembly and Assembly".

1 : Connecting rod
• Measure the inner diameter of connecting rod big end with an
inside micrometer.

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, replace connecting rod assembly. JPBIA0222ZZ

CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).

Standard : Refer to EM-475, "Cylinder Block".

JPBIA0223ZZ

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to EM-475, "Cylinder Block".

JPBIA0218ZZ

Connecting Rod Bushing Oil Clearance

EM-460
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter) A

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, replace connecting rod assembly and/or piston and piston pin assembly. EM
• If replacing piston and piston pin assembly. Refer to “PISTON PROTRUSION”.

PISTON PROTRUSION C
Measure the protrusion of piston with the following procedure:
1. Set piston at a point close to the TDC.
2. Set the dial indicator stand set [commercial service tool: D
KV113B0040 (Mot.251-01)] (B) and [commercial service tool:
KV113B0050 (Mot.252-01)] (A) at the location as shown in the
figure. E
3. Set the indicator scale to “0” where the piston protrusion is max-
imized.
4. Move the dial indicator stand so that the tip of dial indicator can F
contact the cylinder block. Read the difference.

Standard : Refer to EM-475, "Cylinder Block". G

JPBIA1803ZZ

5. If measured value is out of the standard, replace piston. Select a

piston in “Piston Protrusion Grade”. H
A : Date of manufacture
B : Piston grade
I
C : Modification in production suffix
D : Mark engraved
: Engine front
J

Piston Protrusion Grade: JPBIA0589ZZ

Refer to EM-475, "Cylinder Block". K

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter L
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
M
Standard : Refer to EM-475, "Cylinder Block".

O
JPBIA0217ZZ

Piston Pin Outer Diameter

P

EM-461
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to EM-475, "Cylinder Block".

JPBIA0218ZZ

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, replace piston and piston pin an assembly.
NOTE:
Piston is available together with piston pin as assembly.
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C).

A : OK
B : NG

Standard : Refer to EM-475, "Cylinder Block" .

• If it exceeds the standard, replace piston ring, and measure again.
If it still exceeds the standard, also replace piston.
JPBIA0219ZZ

PISTON RING END GAP

• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert (A) piston ring until middle of cylinder with piston, and
measure piston ring end gap with a feeler gauge (B).

C : Measuring point

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, replace piston ring, and measure again.
If it still exceeds the standard, replace cylinder block and piston
rings.
JPBIA0220ZZ

CYLINDER BLOCK TOP SURFACE DISTORTION

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.

EM-462
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
• Measure the distortion on the cylinder block upper face at different
points in six directions (C, D, E, F, G and H) with a straight edge A
(A) and feeler gauge (B).

Standard : Refer to EM-475, "Cylinder Block". EM

• If it exceeds the standard, replace cylinder block.

JPBIA0224ZZ

D
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-447, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing with a bore E
gauge.

1 : Cylinder block F
2 : Main bearing cap

Standard : Refer to EM-475, "Cylinder Block". G

• If it exceeds the standard, replace cylinder block and main bearing
caps assembly.
NOTE: JPBIA0225ZZ
H
Main bearing caps cannot be replaced individually, because it is
machined together with the cylinder block.
PISTON TO CYLINDER BORE CLEARANCE I
Cylinder Bore Inner Diameter
• Using a bore gauge, measure the cylinder bore for wear, out-of-round and taper at six different points on
each cylinder. J

Standard:
Cylinder bore inner diameter K
: Refer to EM-475, "Cylinder Block".
• If it exceeds the standard, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder L
block.
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A). M

Standard : Refer to EM-475, "Cylinder Block".

N
Measure point : Refer to EM-475, "Cylinder Block".

JPBIA0227ZZ P

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter.
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)

Standard : Refer to EM-475, "Cylinder Block".

• If it exceeds the standard, replace piston and piston pin assembly and/or cylinder block.
EM-463
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod bearing cap, and tighten connecting rod cap bolts to
the specified torque. Refer to EM-447, "Disassembly and Assem-
bly".
• Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)

Standard : Refer to EM-479, "Connecting Rod Bear-

ing". JPBIA0230ZZ

• If it exceeds the standard. Replace connecting rod bearing or/and

connecting rod.
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-447, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the standard is
the same as that described in “Method by Calculation”.

JPBIA0231ZZ

MAIN BEARING OIL CLEARANCE

Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap mounting bolts to the specified
torque. Refer to EM-447, "Disassembly and Assembly".
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)

Standard : Refer to EM-479, "Main Bearing".

• If it exceeds the standard, select proper main bearing according to
main bearing inner diameter and crankshaft main journal diameter
to obtain specified bearing oil clearance. Refer to EM-479, "Main JPBIA0232ZZ

Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in the crankshaft axial direction, avoiding
oil holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-447, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.

EM-464
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [R9M]
• Remove main bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width. A
NOTE:
The procedure when the measured value exceeds the standard is
the same as that described in “Method by Calculation”.
EM

JPBIA0231ZZ

D
FLYWHEEL INSPECTION
For a dual mass flywheel which has worked: presence of a free rotation angle. This angle is measured by fix-
ing the primary flywheel and turning the secondary flywheel. The dual mass flywheel free rotation angle must
not exceed 15° or 30mm (1.2 in) in linear movement measured on the edge. E

EM-465