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SERVICE INFORMATION
GENERAL
CRANKSHAFT
/ PISTON/
CYLINDER
•
The
crankca
se must be separated
to service
the crankshaft
and piston/connecting
rod.
Refer to procedures
for
crankcase
separation
(page
11-5)
and
assembly
(page
11-13).
•
Mark
and
store
the
connecting
rods,
bearing caps, pistons
and
bearing
inserts
to be sure of their correct
locations for
reassembly.
•
The crankpin
and main journal bearing
i
nserts are
select
fit and are identified
by color
codes.
Select
replacement
bear-
ings from
the code
tables.
After
selecting
new bearings, recheck the
oil
clearance w
ith
a plastigauge. Incorrect oil clear-
ance
can
cause major engine
damage.
SPECIFICATIONS
Unit: mm
(in)
ITEM
STANDARD
SERVICE LIMIT
! -
Crankshaft
Connecting
rod side clearance
0.10- 0.30
(0.004
-
0.012)
0.40
(0.016)
Runout
-
0.05
(0.002)
Main journal
bearing
oil
clearance
0.019- 0.037
(0.0007-
0.0015)
--
0.05 (0.002
)
Cylinder
I.D,
72.000-72.015
(2.8346-
2.8352)
72.10
(2.839)
Out of round
-
0.10
(0.004)
-
Taper
-
0.10
(0.004i
-
Warpage
--
0.10
(0.004)
-
--
Piston,
piston
Piston
O.D.
at 18 mm
(0.7
in)
from
71.965-71.985 (2.8333- 2.8340)
71.90 (2.831
)
rings
bottom
Piston
pin bore
I.
D.
17.002- 17.008
(0.6694
-
0.6696)
17.02
(0.670)
Piston
pin
O.D.
I
16.994
-
17.000
(0.6691 -
0.6693)
16.98
(0.669)
Piston
-to-piston pin clearance
I
0.002
-
0.014
(0.0001
-
0.0006)
0.04
(0.002)
Piston ring
end
Top
0.20-0.30
(0.008-
0.012)
0.5
(0.02)
gap
Second
0.30- 0.45
(0.012
-
0.01
8)
0.6
(0.02)
Oil
0.20-
0.70 (0.008
-
0.028)
0.9
(0.04)
(side
rail)
Piston
ring -to-ring
Top
0.030-0.065
(0.0012-
0.0026)
0.11 (0.004)
-
groove
clearance
Second
0.015-
0.050
(0.0006- 0.0020)
0.10 (0.004)
0.015- 0.050
(0.0006
-
0.0022)
- -
0.10 (0.004)
Cylinder-to-piston
clearance
Connecting
rod small
end 1.0-:-
17.016- 17.034 (0.6699-
0.6706)
17.04
(0.671)
Connecting rod-to-piston pin
clearance
0.016- 0.040
(0.0006-
0.0016)
0.06
(0.002)
[
Crankpin
bearing
oil
clearance
0.030-0.052
(0.0012-
0.0020)
0.08
(0.003)
- -
TOEOUE VALUES
Connecting
rod bearing
cap nut
33 N·m (3.4
kgf·m,
25
lbf.ft)
Apply
oil to the threads and
seating
sur-
face
TROUBLESHOOTING
Cylinder
compression
is
too
low,
hard
to
starting
or
poor perform
ance
at
low
speed
•
Leaking
cylinder
head
gasket
•
Worn, stuck
or broken
piston
ring
•
Worn
or damaged
cylinder and
piston
Cylinder
compression
too
high,
overheats or
knocks
•
Carbon
deposits
on
the
cylinder head and/or piston
crown
Excessive
smoke
•
Worn cylinder, piston or piston ring
•
Improper installation
of piston rings
•
Scored or
scratched piston
or cylinder
wall
Abnormal noise
•
Worn piston
pin or piston
pin
hole
•
Worn
connecting rod
small
end
•
Worn
cylinder,
piston or piston rings
•
Worn
main
journal
bearings
•
Worn
crankpin
bearings
Engine vibration
•
Excessive crankshaft runout
12-3
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