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Chapter 7 ASSEMBLY OF BASIC ENGINE
2.13 Connecting Rod End Play - Measure
Measure the end play of the connecting rod.
If the value exceeds the limit, find the causal parts, and
replace them with new ones.
Connecting Rod End Play - Measure
2.14 Piston Protrusion - Measure
Measure the protrusion of each piston, following the
instructions below.If the value exceeds the limit, inspect the
clearances between various parts involved.
(1) Move the piston to the top dead center.
(2) Apply the dial gauge probe to the top face of crankcase,
and adjust the dial gauge to zero.
(3) Move the dial gauge to the top face of piston, measure
the maximum protrusion by turning the crankshaft near
top dead center.
Note: The crankshaft position that indicates the maximum
protrusion is defined as the correct top dead center.
(4) Measure the protrusion at four places on the piston top
face, and calculate the mean value.
Note: The top clearance (clearance between the piston top
and cylinder head) can be calculated by the piston pro-
trusion, cylinder liner flange protrusion and cylinder
head gasket thickness.
Top clearance = Cylinder head gasket thickness + Cyl-
inder liner flange protrusion - Piston protrusion
Piston protrusion - Measure
Top clearance
Item Standard value Limit value
Connecting rod end play
0.6 to 0.9 mm
[0.024 to 0.035 in.]
1.0 mm
[0.040 in.]
Connecting rod
Connecting rod end play
Piston protrusion must always meet the standard, as
the amount of protrusion not only influences engine
performance, but it also prevents valve from stamping.
Item Standard value
Piston protrusion 0.229 to 0.839 mm [0.0090 to 0.0330 in.]
Cylinder liner flange
protrusion
0.10 to 0.19 mm [0.0039 to 0.0075 in.]
Thickness of cylin-
der head gasket
1.77 to 1.83 mm [0.0697 to 0.0720 in.]
Top clearance 1.191 to 2.031 mm [0.0469 to 0.0800 in.]
Piston protrusion
Cylinder head
Cylinder liner
Cylinder liner
Cylinder liner flange
protrusion
Cylinder liner flange
protrusion
Crankcase
Crankcase
Piston protrusion
Piston protrusion
Top clearance
Top clearance
Cylinder head gasket
thickness
Cylinder head gasket
thickness
Cylinder head
Piston
Piston
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