Procedures
HOW TO SELECT PISTON AND BEARINGDescription
For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only "0" grade is available.) The information at the shipment from the plant is described as a reference.
^ The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts.
^ For reused or repaired parts, measure the dimension accurately Determine the grade by comparing the measurement with the values of each selection table.
^ For details of the measurement method of each part, the reuse standards and the selection method of the selective fitting parts, refer to the text.
Piston
WHEN NEW CYLINDER BLOCK IS USED
^ Check the cylinder bore grade ("1", "2" or "3") on rear side of cylinder block, and select piston of the same grade.
A: Bearing housing grade No. 1
B: Bearing housing grade No. 2
C: Bearing housing grade No. 3
D: Bearing housing grade No. 4
E: Cylinder bore grade No. 1
F: Cylinder bore grade No. 2
G: Cylinder bore grade No. 3
H: Cylinder bore grade No. 4
I: Cylinder bore grade No. 5
J: Cylinder bore grade No. 6
K: Identification
<---: Engine front
NOTE:
Piston is available with piston pin as a set for the service part. (Only "0" grade piston pin is available.)
WHEN NEW CYLINDER BLOCK IS REUSED
1. Measure the cylinder bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "PISTON SELECTION TABLE".
A: Piston grade number
B: Front mark
C: Piston pin grade number
3. Select piston of the same grade.
PISTON SELECTION TABLE
NOTE:
^ Piston is available together with piston pin as assembly.
^ Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only "0" grade is available.)
^ No second grade mark is available on piston.
Connecting Rod Bearing
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Apply connecting rod big end diameter grade stamped (D) on connecting rod side face to the row in the "CONNECTING ROD BEARING SELECTION TABLE".
A: Sample codes
B: Bearing stopper groove
C: Small-end diameter grade
E: Weight grade
F: Cylinder No.
G: Management code
H: Front mark
I: Management code
2. Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the "CONNECTING ROD BEARING SELECTION TABLE"
A: Journal diameter grade No. 1
B: Journal diameter grade No. 2
C: Journal diameter grade No. 3
D: Journal diameter grade No. 4
E: Pin diameter grade No. 1
F: Pin diameter grade No. 2
G: Pin diameter grade No. 3
H: Pin diameter grade No. 4
I: Pin diameter grade No. 5
J: Pin diameter grade No. 6
K: Identification
3. Read the symbol at the cross point of selected row and column in the "CONNECTING ROD BEARING SELECTION TABLE".
4. Apply the symbol obtained to the "CONNECTING ROD BEARING GRADE TABLE" to select connecting rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the connecting rod big end diameter.
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter.
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in "Crankshaft pin journal diameter" column of "CONNECTING ROD BEARING SELECTION TABLE".
5. Select connecting rod bearing of the same grade.
CONNECTING ROD BEARING GRADE TABLE
Connecting rod bearing grade table: Refer to EM-149, "Connecting Rod Bearing". Connecting Rod Bearing
UNDERSIZE BEARING USAGE GUIDE
^ When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings.
^ When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].
Bearing undersize table: Refer to EM-149, "Connecting Rod Bearing". Connecting Rod Bearing
Main Bearing
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED
1. "MAIN BEARING SELECTION TABLE" rows correspond to bearing housing grade on rear left side of cylinder block.
A: Bearing housing grade No. 1
B: Bearing housing grade No. 2
C: Bearing housing grade No. 3
D: Bearing housing grade No. 4
E: Cylinder bore grade No. 1
F: Cylinder bore grade No. 2
G: Cylinder bore grade No. 3
H: Cylinder bore grade No. 4
I: Cylinder bore grade No. 5
J: Cylinder bore grade No. 6
K: Identification code
<---: Engine front
2. "MAIN BEARING SELECTION TABLE" columns correspond to journal diameter grade on front side of crankshaft.
A: Journal diameter grade No. 1
B: Journal diameter grade No. 2
C: Journal diameter grade No. 3
D: Journal diameter grade No. 4
E: Pin diameter grade No. 1
F: Pin diameter grade No. 2
G: Pin diameter grade No. 3
H: Pin diameter grade No. 4
I: Pin diameter grade No. 5
J: Pin diameter grade No. 6
K: Identification code
3. Select main bearing grade at the point where selected row and column meet in "MAIN BEARING SELECTION TABLE".
4. Apply sign at crossing in above step 3 to "MAIN BEARING GRADE TABLE".
NOTE:
^ "MAIN BEARING GRADE TABLE" applies to all journals.
^ Service parts is available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter.
2. Correspond the measured dimension in "Cylinder block main bearing housing inner diameter" row of "MAIN BEARING SELECTION TABLE".
3. Correspond the measured dimension in "Crankshaft main journal diameter" column of "MAIN BEARING SELECTION TABLE".
4. Follow step 3 and later in "When New Cylinder Block and Crankshaft are Used".
MAIN BEARING GRADE TABLE (ALL JOURNALS)
Main bearing grade table (All journals): Refer to EM-148, "Main Bearing". Main Bearing
UNDERSIZE BEARING USAGE GUIDE
^ When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing.
^ When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].
Bearing undersize table: Refer to EM-148, "Main Bearing". Main Bearing