Piston pin and pin bore

Using a small bore gauge, measure the piston pin bore inside diameter, and using a micrometer, measure the piston pin outside diameter. If the difference between these two measure­ ments is more than the limits, replace both piston and piston pin.

Piston pin bore l.D.

Service Limit: 16.030 mm (0.6311 in)

09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22401: Small bore gauge (10 - 18 mm)

0.4 m m 0.S.

1.0 m m O.S.

Using a micrometer, measure the piston pin outside diameter

at three positions.

Piston pin O.D.

Service Limit: 15.980 mm (0.6291 in) 09900-20205: Micrometer (O - 25 mm)

Using a small bore gauge, measure the conrod small end inside diameter.

09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22401: Small bore gauge (10 - 18 mm)

Conrod small end l.D.

Service Limit: 16.040 mm (0.6315 in)

CONROD BIG END SIDE CLEARANCE

Check the conrod side clearance by using a thickness gauge. If the clearance exceeds the limit, replace con rod or crankshaft.

Service Limit: 0.3 mm (0.01 in) 09900-20803: Thickness gauge

Big end width: 16.95 - 17.00 mm (0.667 - 0.669 in)

Standard

Crank pin width: 17.10 - 17.15 mm (0.673 - 0.675 in)

09900-20205: Micrometer (0 - 25 mm)

09900-20605: Dial calipers (10 - 34 mm)

• Loosen the bearing cap nuts, and tap the bolt end lightly with plastic hammer to remove bearing cap.

• R emove the rods, and mark them to identify the cylinder position.

• Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings.

Never try to remove or loosen the conrod cap bolts due to their possible loosening in the rod. Once displaced, the bearing cap will not be fitted properly.

• Place plastigauge axially on the crank pin avoiding oil hole and at the TDC or BDC side as shown.

• Tighten the bearing cap with two-step to torque values.

Initial tightening torque: 12 - 14 N-m

(1.2 - 1.4 kg-m, 8.5 - 10.0 lb-ft)

(2.85 -3.15 kg-m, 20.5 -23.0 lb-ft)

09900-22301: Plastigauge

NOTE:

When fitting bearing cap to crank pin, be sure to discriminate one end from the other, namely front and rear.

NOTE:

Never rotate the crankshaft or conrod when a piece of plasti­ gauge is in the clearance.

• R emove the caps, and measure the width of compressed plastigauge with envelope scale. This measurement should be taken at the widest part.

Crank pin bearing oil clearance

Standard: 0.024 - 0.048 mm (0.0009 - 0.0019 in)

Service Limit: 0.080 mm (0.0031 in)

• If oil clearance exceeds the service limit, select the specified bearings from the following table.

• Check the corresponding rod l.D. code number CD, " 1" or

''2''.

• Check the corresponding crank pin O.D. code number ®,

" 1'', " 2" or ''3''.

CD

Conrod l.D. specification

Bearing thickness

CAUTION:

Bearing should be replaced as a set.