If a new connecting rod is used
Select a connecting rod bearing that matches the journal diameter class of the crankshaft used, according to section «Connecting rod bearing selection procedure», see below.
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Warping of the surface of the cylinder block
Remove all traces of sealant, old gasket, oil, etc. from the contact surface of the cylinder block.
Attention:
Keep sealant residues away from oil and water passages.
Check the warping of the contact surface of the cylinder block in 6 different directions.
- Limit Warping: 0.1mm
Main bearing housing inner diameter
Install main bearing caps without bearings and tighten mounting bolts to specification.
Using an inside gauge, measure the inside diameter of the main bearing housing.
- Standard diameter: 58.944-58.968 mm
If the diameter is out of specification, replace the cylinder block and main bearing caps.
Note: These components cannot be changed individually.
Clearance between piston and cylinder wall
Cylinder inner diameter
Using a bore gauge, check each cylinder for wear, out-of-roundness and taper in 6 different positions: along the X and Y axes at points A, B and C (top, center and bottom).
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If the measured values are higher than the specified values, or if there are burrs or burn marks on the inner walls of the cylinder, hone the cylinders.
Oversized pistons available (by 0.2 mm). When using an oversized piston, honing so that the clearance between the piston and the cylinder wall is correct. In addition, use oversized piston rings to match the oversized piston.
Piston outer diameter
Using a micrometer, measure the outside diameter of the piston skirt.
- Measuring point: 45 mm down from the piston crown
- Standard diameter: 85.980-86.010 mm
Calculation of clearance between piston and cylinder wall
Make calculations based on the outer diameter of the piston skirt and the inner diameter of the cylinder (X-axis, point B).
(Gap) = (Cylinder diameter) - (Outer skirt diameter)
- Standard clearance: 0.010-0.030mm
If the clearance is excessive, replace the piston and piston pin assembly.