CYLINDER BLOCK
Mechanical
20. Cylinder Block
S183090
11) Remove flywheel (MT vehicle) or drive plate
(AT vehicle).
Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
• MT VEHICLES
A: REMOVAL
S183090A18
NOTE:
Before conducting this procedure, drain engine oil
completely if applicable.
1)   Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.>
2)   Remove V-belt. <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.>
3)   Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.>
4)   Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.>
5)   Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.>
for_01_22-501.jpg
• AT VEHICLES
6)   Remove camshaft ME(DOHC TURBO)-56, Sprocket.>
7)   Remove crankshaft
sprocket. <Ref. to REMOVAL, Camshaft
sprocket. <Ref. to
for_01_22-502.jpg
ME(DOHC TURBO)-57, REMOVAL, Crankshaft Sprocket.>
8)   Remove generator and A/C compressor with their brackets.
9)   Remove cylinder head assembly. <Ref. to ME(DOHC TURBO)-63, REMOVAL, Cylinder Head Assembly.>
10)   Remove clutch housing cover. (MT vehicles only)
12)   Remove oil separator cover.
13)   Remove water by-pass pipe for heater.
14)   Remove oil filter.
ME(DOHC TURBO)-70
CYLINDER BLOCK
Mechanical
15) Remove oil cooler.
17)   Remove oil strainer stay.
18)   Remove oil strainer.
19)   Remove baffle plate.
20)   Remove water pips.
21)   Remove water pump.
22)   Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in figure when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
for_01_22-503.jpg
for_01_22-504.jpg
(A)    Gasket
(B)    Oil cooler
(C)    Connector
16) Removal of oil pan
(1)  Turn cylinder block with #2 and #4 piston sides facing upward.
(2)   Remove bolts which secure oil pan to cylin­der block.
(3)   Insert a oil pan cutter blade between cylin­der block-to-oil pan clearance and remove oil pan.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
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ME(DOHC TURBO)-71
CYLINDER BLOCK
Mechanical
for_01_22-506.jpg
(1)    Service hole plug
(2)    Gasket
(3)    Circlip
(4)    Piston pin
(5)    Service hole cover
(6)    O-ring
24) Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
23) Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
for_01_22-507.jpg
for_01_22-508.jpg
ME(DOHC TURBO)-72
CYLINDER BLOCK
Mechanical
25) Draw out piston pin from #1 and #2 pistons
using ST.
ST 499097700 PISTON PIN REMOVER
CAUTION:
Be careful not to confuse original combination
of piston, piston pin and cylinder.
26)  Similarly remove piston pins from #3 and #4 pistons.
27)   Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.
28)   Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
29)  Set up cylinder block so that #1 and #3 cylin­ders are on the upper side, then remove cylinder block connecting bolts.
30)  Separate left-hand and right-hand cylinder blocks.
CAUTION:
When separating cylinder block, do not allow the connecting rod to fall and damage the cyl­inder block.
for_01_22-509.jpg
for_01_22-510.jpg
(1)    Cylinder block
(2)    Rear oil seal
(3)    Crankshaft
(4)    Crankshaft bearing
(5) Piston
31)   Remove rear oil seal.
32)   Remove crankshaft together with connecting rod.
33)   Remove crankshaft bearings from cylinder block using hammer handle.
CAUTION:
Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
34) Draw out each piston from cylinder block using wooden bar or hammer handle.
ME(DOHC TURBO)-73
CYLINDER BLOCK
Mechanical
CAUTION:
Do not confuse combination of piston and cyl­inder.
B: INSTALLATION
S183090A11
for_01_22-511.jpg
(1)    Crankshaft bearing
(2)    Crankshaft
(3)    Cylinder block
(4) Rear oil seal
Tightening torque: N-m (kgf-m, ft-lb) T1: 25 (2.5, 18.1) T2: 47 (4.8, 34.7)
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
CAUTION:
Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
1)   Position crankshaft on the #2 and #4 cylinder block.
2)  Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
for_01_22-512.jpg
ME(DOHC TURBO)-74
CYLINDER BLOCK
Mechanical
3) Temporarily tighten 10 mm cylinder block con­necting bolts in alphabetical sequence shown in figure.
6) Install rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
for_01_22-513.jpg
for_01_22-514.jpg
4) Tighten 10 mm cylinder block connecting bolts in alphabetical sequence.
Tightening torque:
47 Nm (4.8 kgf-m, 34.7 ft-lb)
7) Position the top ring gap at (A) or (B) in the fig­ure.
for_01_22-515.jpg
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8)   Position the second ring gap at 180° on the reverse side for the top ring gap.
9)   Position the upper rail gap at (C) or (D) in the figure.
5) Tighten 8 mm and 6 mm cylinder block connect­ing bolts in alphabetical sequence shown in figure.
Tightening torque:
(A) — (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
for_01_22-517.jpg
for_01_22-518.jpg
10) Position the expander gap at 180° of the reverse side for the upper rail gap.
ME(DOHC TURBO)-75
CYLINDER BLOCK
Mechanical
11) Position the lower rail gap at (E) or (F) in the figure.
CAUTION:
•  Ensure ring gaps do not face the same direc­tion.
•  Ensure ring gaps are not within the piston skirt area.
for_01_22-519.jpg
12) Install circlip.
Install circlips in piston holes located opposite ser­vice holes in cylinder block, when positioning all pistons in the corresponding cylinders.
CAUTION:
Use new circlips.
for_01_22-520.jpg
CAUTION:
Piston front mark faces towards the front of the
engine.
for_01_22-521.jpg
(A) Front mark
ME(DOHC TURBO)-76
CYLINDER BLOCK
Mechanical
for_01_22-522.jpg
(1)    Piston
(2)    Piston pin
(3)    Circlip
(4)    Gasket
(5)    Service hole plug
Tightening torque: N-m (kgf-m, ft-lb) T: 69 (7.0, 50.6)
(1) Insert ST3 into service hole to align piston pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before inser­tion.
ST3 499017100 PISTON PIN GUIDE
13) Installing piston
(1)  Turn cylinder block so that #1 and #2 cylin­ders face upward.
(2)   Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead cen­ter.
ST1 499987500 CRANKSHAFT SOCKET
(3)  Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2.
ST2 498744300 PISTON GUIDE
for_01_22-523.jpg
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(2) Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole.
14) Installing piston pin
ME(DOHC TURBO)-77
CYLINDER BLOCK
Mechanical
(3) Install circlip.
CAUTION:
Use new circlips.
for_01_22-525.jpg
(4) Apply fluid packing around the service hole plug.
Fluid packing:
THREE BOND 1215 or equivalent
for_01_22-526.jpg
(5) Install service hole plug and gasket.
CAUTION:
Use a new gasket.
for_01_22-527.jpg
ME(DOHC TURBO)-78
CYLINDER BLOCK
Mechanical
for_01_22-528.jpg
(1)    Piston
(2)    Piston pin
(3)    Circlip
(4)    Gasket
(5)    Service hole plug
(6)    Service hole cover
(7)    O-ring
Tightening torque: N-m (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 69 (7.0, 50.6)
(6) Turn cylinder block so that #3 and #4 cylin­ders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.
15)   Install water pipe.
16)   Install baffle plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
17)   Install oil strainer and O-ring
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
18)   Install oil strainer stay.
19) Apply fluid packing to matching surfaces and install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
for_01_22-529.jpg
ME(DOHC TURBO)-79
CYLINDER BLOCK
Mechanical
20) Apply fluid packing to matching surfaces and install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
ST 499587100 OIL SEAL INSTALLER
for_01_22-530.jpg
for_01_22-531.jpg
(2) Apply fluid packing to matching surface of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
21) Install flywheel (MT vehicles) or drive plate (AT
vehicles).
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
• MT VEHICLES
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for_01_22-533.jpg
(A) O-ring
(3) Apply a coat of engine oil to the inside of the oil seal.
for_01_22-534.jpg
• AT VEHICLES
for_01_22-535.jpg
(4) Install oil pump on cylinder block. Be care­ful not to damage oil seal during installation.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
•  Do not forget to install O-ring and seal when installing oil pump.
•  Align flat surface of oil pump's inner rotor with crankshaft before installation.
24) Install water pump and gasket.
22)   Install clutch housing cover.
23)   Installation of oil pump
(1) Discard front oil seal after removal. Replace with a new one using ST.
ME(DOHC TURBO)-80
CYLINDER BLOCK
Mechanical
Tightening torque:
First; 12 Nm (1.2 kgf-m, 8.7 ft-lb) Second; 12 Nm (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
•  Be sure to use a new gasket.
•  When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
28) Install water by-pass pipe between oil cooler and water pump.
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29)   Install water pipe.
CAUTION:
Always use a new O-ring.
30)   Install cylinder head assembly. <Ref. to ME(DOHC TURBO)-63, INSTALLATION, Cylinder Head Assembly.>
31)   Install oil level gauge guide and tighten attach­ing bolt (left side only).
32)   Install rocker cover.
33)   Install crankshaft sprocket. <Ref. to ME(DOHC TURBO)-57, INSTALLATION, Crank­shaft Sprocket.>
34)   Install camshaft sprocket. <Ref. to ME(DOHC TURBO)-56,          INSTALLATION,          Camshaft Sprocket.>
35)   Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assembly.>
36)   Install belt cover. <Ref. to ME(DOHC TURBO)-47, INSTALLATION, Belt Cover.>
37)   Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.>
38)   Install generator and A/C compressor brackets on cylinder head.
39)   Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
40)   Install intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.>
25)   Install water by-pass pipe for heater.
26)   Install oil cooler.
Tightening torque:
T1: 55 Nm (5.5 kgf-m, 40 ft-lb) T2: 69 Nm (7.0 kgf-m, 50.6 ft-lb)
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(A)    O-ring
(B)    Oil cooler
(C)    Connector
27) Install oil filter using ST.
ST 498547000 OIL FILTER WRENCH
ME(DOHC TURBO)-81
CYLINDER BLOCK
Mechanical
C: DISASSEMBLY
S183090A06
for_01_22-539.jpg
(1)    Connecting rod cap
(2)    Connecting rod bearing
(3)    Top ring
(4)    Second ring
(5)    Oil ring
(6)    Circlip
1)   Remove connecting rod cap.
2)   Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confu­sion.
3)   Remove piston rings using the piston ring expander.
4)   Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5)   Remove circlip.
ME(DOHC TURBO)-82
CYLINDER BLOCK
Mechanical
D: ASSEMBLY
S183090A02
for_01_22-540.jpg
(1)    Connecting rod bearing
(2)    Connecting rod
(3)    Connecting rod cap
(4)    Oil ring
(5)    Second ring
(6)    Top ring
(7)    Circlip
Tightening torque: N-m (kgf-m, ft-lb) T: 44.6 (4.55, 32.9)
1)   Install connecting rod bearings on connecting rods and connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod
bearings.
2)   Install connecting rod on crankshaft.
CAUTION:
Position each connecting rod with the side
marked facing forward.
3)   Install connecting rod cap with connecting rod nut.
Ensure the arrow on connecting rod cap faces the front during installation.
CAUTION:
•  Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number.
•  When tightening the connecting rod nuts, apply oil on the threads.
4)   Install oil ring spacer, upper rail and lower rail in this order by hand. Then install second ring and top ring with a piston ring expander.
E: INSPECTION
S183090A10
1. CYLINDER BLOCK
S183090A1001
1)  Visually check for cracks and damage. Especially, inspect important parts by means of red lead check.
2)  Check the oil passages for clogging.
3)   Inspect crankcase surface that mates with cyl­inder head for warping by using a straight edge, and correct by grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block: 201.0 mm (7.91 in)
ME(DOHC TURBO)-83
CYLINDER BLOCK
Mechanical
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylin­der block's front upper surface.
CAUTION:
Measurement should be performed at a tem­perature 20°C (68°F).
NOTE:
Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line in selecting a standard piston.
Standard diameter:
A: 92.005 — 92.015 mm (3.6222 — 3.6226
in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222
in)
2) How to measure the inner diameter of each
cylinder
Measure the inner diameter of each cylinder in
both the thrust and piston pin directions at the
heights shown in the figure, using a cylinder bore
gauge.
CAUTION:
Measurement should be performed at a tem­perature 20°C (68°F).
Taper: Standard
0.015 mm (0.0006 in) Limit
0.050 mm (0.0020 in)
Out-of-roundness: Standard
0.010 mm (0.0004 in) Limit
0.050 mm (0.0020 in)
for_01_22-541.jpg
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(A)     Main jourual size mark
(B)    Cylinder block RH-LH combination mark
(C)    #1 cylinder bore size mark
(D)    #2 cylinder bore size mark
(E)    #3 cylinder bore size mark
(F)    #4 cylinder bore size mark
(A)     Piston pin direction
(B)    Thrust direction
3)  When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4)   How to measure the outer diameter of each piston
Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction)
CAUTION:
Measurement should be performed at a tem­perature of 20°C (68°F).
ME(DOHC TURBO)-84
CYLINDER BLOCK
Mechanical
Piston grade point H: 37.0 mm (1.457 in)
Piston outer diameter:
Standard
A: 91.985 — 91.995 mm (3.6214 —3.6218 in) B: 91.975 — 91.985 mm (3.6211 — 3.6214 in)
0.25 mm (0.0098 in) oversize 92.225 — 92.235 mm (3.6309 —3.6313 in)
0.50 mm (0.0197 in) oversize 92.475 — 92.485 mm (3.6407—3.6411 in)
CAUTION:
Immediately after reboring, the cylinder diam­eter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter.
Limit of cylinder enlarging (boring): 0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1)  Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective.
2)   Measure the piston-to-cylinder clearance at each cylinder. <Ref. to ME(DOHC TURBO)-84, CYLINDER AND PISTON, INSPECTION, Cylinder Block.> If any of the clearances is not to specification, replace the piston or bore the cylin­der to use an oversize piston.
3)   Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective.
Standard clearance between piston pin and hole in piston: Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in) Limit
0.020 mm (0.0008 in)
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5)  Calculate the clearance between cylinder and piston.
CAUTION:
Measurement should be performed at a tem­perature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68°F): Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit
0.050 mm (0.0020 in)
6)   Boring and honing
(1)   If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an over­size piston for one cylinder only.
(2)   If the cylinder inner diameter exceeds the limit after boring and honing, replace the crank-case.
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ME(DOHC TURBO)-85
CYLINDER BLOCK
Mechanical
4) Check circlip installation groove on the piston for burr (A). If necessary, remove burr from the groove so that piston pin can lightly move.
• The oil ring is a combined ring consisting of two rails and a spacer in between. When installing, be careful to assemble correctly.
for_01_22-545.jpg
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5) Check piston pin circlip for distortion, cracks and wear.
(A)
Top ring
(B)
Second ring
(C)
Oil ring
(a)
Upper rail
(b)
Spacer
(c)
Lower rail
4. PISTON RING
S183090A1004
1) If piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston.
CAUTION:
• "N" is marked on the end of the top and sec­ond rings. When installing the rings to the piston, face this mark upward.
2) Squarely place piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
Unit: mm (in)
Standard
Limit
Piston ring gap
Top ring
0.20 — 0.35 (0.0079 — 0.0138)
1.0 (0.039)
Second ring
0.35 — 0.50 (0.0138 — 0.0197)
1.0 (0.039)
Oil ring rail
0.20 — 0.70 (0.0079 — 0.0276)
1.5 (0.059)
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ME(DOHC TURBO)-86
CYLINDER BLOCK
Mechanical
3) Measure the clearance between piston ring and piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the pis­ton ring groove and piston ring.
5. CONNECTING ROD
S183090A1005
1)   Replace connecting rod, if the large or small end thrust surface is damaged.
2)  Check for bend or twist using a connecting rod aligner. Replace connecting rod if the bend or twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in length:
0.10 mm (0.0039 in)
Unit: mm (in)
Standard
Limit
Clearance between pis­ton ring and piston ring groove
Top ring
0.040 — 0.080 (0.0016 — 0.0031)
0.15 (0.0059)
Second ring
0.030 — 0.070 (0.0012 — 0.0028)
0.15 (0.0059)
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(A)    Thickness gauge
(B)    Connecting rod
3) Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit.
Connecting rod side clearance: Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in) Limit
0.4 mm (0.016 in)
for_01_22-551.jpg
ME(DOHC TURBO)-87
CYLINDER BLOCK
Mechanical
4)   Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5)   Measure the oil clearance on individual con­necting rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.)
Connecting rod oil clearance: Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in) Limit
0.05 mm (0.0020 in)
6) Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end.
Clearance between piston pin and bushing: Standard
0 — 0.022 mm (0 — 0.0009 in) Limit
0.030 mm (0.0012 in)
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Unit: mm (in)
Bearing
Bearing size (Thickness at cen­ter)
Outer diameter of crank pin
Standard
1.492— 1.501 (0.0587 — 0.0591)
51.984 — 52.000 (2.0466 — 2.0472)
0.03 (0.0012) undersize
1.510— 1.513 (0.0594 — 0.0596)
51.954 — 51.970 (2.0454 — 2.0461)
0.05 (0.0020) undersize
1.520— 1.523 (0.0598 — 0.0600)
51.934 — 51.950 (2.0446 — 2.0453)
0.25 (0.0098) undersize
1.620— 1.623 (0.0638 — 0.0639)
51.734 — 51.750 (2.0368 — 2.0374)
7) Replacement procedure is as follows.
(1)   Remove bushing from connecting rod with ST and press.
(2)   Press bushing with ST after applying oil on the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH­ING REMOVER AND INSTALLER
for_01_22-553.jpg
(3)   Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing.
(4)  After completion of reaming, clean bushing to remove chips.
ME(DOHC TURBO)-88
CYLINDER BLOCK
Mechanical
6. CRANKSHAFT AND CRANKSHAFT
3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace bearing with a suitable (undersize) one, and replace or recondition crankshaft as neces­sary. When grinding crank journal or crank pin, fin­ish them to the specified dimensions according to the undersize bearing to be used.
Crank pin and crank journal: Out-of-roundness
0.020 mm (0.0008 in) or less Taper limit
0.07 mm (0.0028 in) Grinding limit
0.250 mm (0.0098 in)
S183090A1006
BEARING
1)  Clean crankshaft completely and check for cracks by means of red lead check etc., and replace if defective.
2)   Measure the crankshaft bend, and correct or replace if it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position crankshaft on these bearings and measure crankshaft bend using a dial gauge.
Crankshaft bend limit: 0.035 mm (0.0014 in)
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Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5
#2, #4
Standard
Journal O.D.
59.992 — 60.008 (2.3619 — 2.3625)
59.992 — 60.008 (2.3619 — 2.3625)
51.984 — 52.000 (2.0466 — 2.0472)
Bearing size (Thickness at cen­ter)
1.998 — 2.011 (0.0787 — 0.0792)
2.000 — 2.013 (0.0787 — 0.0793)
1.492— 1.510 (0.0587 — 0.0591)
0.03 (0.0012) undersize
Journal O.D.
59.962 — 59.978 (2.3607 — 2.3613)
59.962 — 59.978 (2.3607 — 2.3613)
51.954 — 51.970 (2.0454 — 2.0461)
Bearing size (Thickness at cen­ter)
2.017 — 2.020 (0.0794 — 0.0795)
2.019 — 2.022 (0.0795 — 0.0796)
1.510— 1.513 (0.0594 — 0.0596)
0.05 (0.0020) undersize
Journal O.D.
59.942 — 59.958 (2.3599 — 2.3605)
59.942 — 59.958 (2.3599 — 2.3605)
51.934 — 51.950 (2.0446 — 2.0453)
Bearing size (Thickness at cen­ter)
2.027 — 2.030 (0.0798 — 0.0799)
2.029 — 2.032 (0.0799 — 0.0800)
1.520— 1.523 (0.0598 — 0.0600)
0.25 (0.0098) undersize
Journal O.D.
59.742 — 59.758 (2.3520 — 2.3527)
59.742 — 59.758 (2.3520 — 2.3527)
51.734 — 51.750 (20368 — 2.0374)
Bearing size (Thickness at cen­ter)
2.127 — 2.130 (0.0837 — 0.0839)
2.129 — 2.132 (0.0838 — 0.0839)
1.620— 1.623 (0.0638 — 0.0639)
O.D. ... Outer Diameter
ME(DOHC TURBO)-89
CYLINDER BLOCK
Mechanical
4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing.
Crankshaft thrust clearance: Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit
0.25 mm (0.0098 in)
5)   Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
6)   Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measure­ment is not within the specification, replace defec­tive bearing with an undersize one, and replace or recondition crankshaft as necessary.
Unit: mm (in)
Crankshaft oil clearance
Standard
0.010 — 0.030(0.0004 — 0.0012)
Limit
0.040 (0.0016)
for_01_22-556.jpg
ME(DOHC TURBO)-90