CYLINDER BLOCK INSPECTION

PROCEDURE


  1. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A01W2MA

      Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head gasket.

      Maximum Warpage
      0.05 mm (0.00197 in.)

      If the warpage is more than the maximum, replace the cylinder block sub-assembly.

  2. INSPECT CYLINDER BORE


    1. A01W26CE02
      Text in Illustration
      *a Axial Direction
      *b Thrust Direction
      *c 10 mm (0.394 in.)
      *d Center
      B001O8N Front

      Using a cylinder gauge, measure the cylinder bore diameter at positions (A) and (B) in the thrust and axial directions.

      Reference Diameter (New Parts)
      86.000 to 86.013 mm (3.38582 to 3.38633 in.)
      Maximum Diameter
      86.13 mm (3.39094 in.)

      If the average diameter of the 4 positions is more than the maximum, replace the cylinder block sub-assembly.

  3. INSPECT PISTON


    1. A01W3K8

      Using a gasket scraper, remove any carbon from the piston top.

    2. A01VZGR

      Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

    3. A01W51F

      Using a brush and solvent, thoroughly clean the piston.

      Note

      Do not use a wire brush.

    4. A01W1VBE02
      Text in Illustration
      *a Distance

      Using a micrometer, measure the piston diameter at a right angle to the piston center line where the distance from the bottom of the piston is as specified.

      Distance
      8.5 mm (0.335 in.)
      Reference Piston Diameter (New Parts)
      85.971 to 86.001 mm (3.38 to 3.39 in.)

      If the diameter is less than the minimum, replace the piston.

  4. INSPECT PISTON OIL CLEARANCE


    1. Measure the cylinder bore diameter in the thrust direction.

    2. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

      Reference Oil Clearance (New Parts)
      0.025 to 0.048 mm (0.000984 to 0.00189 in.)
      Maximum Oil Clearance
      0.10 mm (0.00394 in.)

      If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly.

  5. INSPECT RING GROOVE CLEARANCE


    1. A01W0VC

      Using a feeler gauge, measure the clearance between a new piston ring set and the wall of the ring groove.

      Standard Ring Groove Clearance
      Item Specified Condition
      No. 1 compression ring

      0.020 to 0.070 mm

      (0.000787 to 0.00276 in.)
      No. 2 compression ring

      0.020 to 0.060 mm

      (0.000787 to 0.00236 in.)
      Oil ring

      0.070 to 0.150 mm

      (0.00276 to 0.00591 in.)

      If the groove clearance is not as specified, replace the piston.

  6. INSPECT PISTON RING END GAP


    1. A01W3VTE01
      Text in Illustration
      *a Piston Ring
      *b 120 mm (4.72 in.)

      Insert the piston ring into the cylinder bore.

    2. Using a piston, push in the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block sub-assembly.

    3. A01W4D4

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 compression ring 0.20 to 0.25 mm (0.00787 to 0.00984 in.)
      No. 2 compression ring 0.32 to 0.37 mm (0.0126 to 0.0146 in.)
      Oil ring 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 compression ring 0.81 mm (0.0319 in.)
      No. 2 compression ring 0.90 mm (0.0354 in.)
      Oil ring 1.40 mm (0.0551 in.)

      If the end gap is more than the maximum, replace the piston ring set. If the end gap is more than the maximum even with a new piston ring set, replace the cylinder block sub-assembly.

  7. INSPECT PISTON PIN OIL CLEARANCE


    1. Check each mark on the piston, piston pin and connecting rod sub-assembly.

      A01W0SWE02
      Text in Illustration
      *a Front Mark *b Piston Pin Hole Inside Diameter Mark
      *c Connecting Rod Small End Bush Inside Diameter Mark - -
    2. A01W3OV

      Using a caliper gauge, measure the inside diameter of the piston pin hole.

      Standard Piston Pin Hole Inside Diameter
      Mark Specified Condition
      A 22.001 to 22.004 mm (0.86618 to 0.86630 in.)
      B 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
      C 22.008 to 22.010 mm (0.86645 to 0.86653 in.)
    3. A01W316E23
      Text in Illustration
      *a 5.0 mm (0.197 in.)
      *b 28 mm (1.10 in.)

      Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter
      Mark Specified Condition
      A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
      B 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
      C 22.004 to 22.006 mm (0.86630 to 0.86638 in.)

      If the diameter is not as specified, replace the piston pin.

    4. A01W100

      Using a caliper gauge, measure the inside diameter of the connecting rod small end bush.

      Standard Connecting Rod Small End Bush Inside Diameter
      Mark Specified Condition
      A 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
      B 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
      C 22.012 to 22.014 mm (0.86661 to 0.86669 in.)

      If the diameter is not as specified, replace the connecting rod sub-assembly.

    5. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

      Standard Oil Clearance
      0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
      Maximum Oil Clearance
      0.013 mm (0.000512 in.)

      If the oil clearance is more than the maximum, replace the piston and piston pin as a set.

    6. Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement.

      Standard Oil Clearance
      0.005 to 0.011 mm (0.000197 to 0.000433 in.)
      Maximum Oil Clearance
      0.017 mm (0.000669 in.)

      If the oil clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, replace the connecting rod sub-assembly and piston pin as a set.

  8. INSPECT CONNECTING ROD SUB-ASSEMBLY


    1. A01W02K

      Using a connecting rod aligner and feeler gauge, check the connecting rod sub-assembly alignment.


      1. Check for misalignment.

        Maximum Misalignment
        0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

        If the misalignment is more than the maximum, replace the connecting rod sub-assembly.

      2. A01W3GA

        Check for twist.

        Maximum Twist
        0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

        If the twist is more than the maximum, replace the connecting rod sub-assembly.

  9. INSPECT CRANKSHAFT


    1. Inspect for runout.


      1. Clean the crank journal.

      2. Place the crankshaft on V-blocks.

      3. A01W4SS

        Using a dial indicator and V-blocks, measure the runout as shown in the illustration.

        Maximum Runout
        0.03 mm (0.00118 in.)

        If the runout is more than the maximum, replace the crankshaft.

    2. A01W0NX

      Inspect the main journals.


      1. Using a micrometer, measure the diameter of each main journal.

        Standard Main Journal Diameter
        54.988 to 55.000 mm (2.16 to 2.17 in.)

        If the diameter is not as specified, check the crankshaft oil clearance. If necessary, replace the crankshaft.

      2. Check each main journal for taper and out-of-round as shown in the illustration.

        Maximum Taper and Out-of-round
        0.003 mm (0.000118 in.)

        If the taper or out-of-round is more than the maximum, replace the crankshaft.

    3. A01VZI4

      Inspect the crank pin.


      1. Using a micrometer, measure the diameter of each crank pin.

        Standard Crank Pin Diameter
        51.492 to 51.500 mm (2.02724 to 2.02756 in.)
        If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft.

      2. Inspect each crank pin for taper and out-of-round as shown in the illustration.

        Maximum Taper and Out-of-round
        0.003 mm (0.000118 in.)

        If the taper or out-of-round is more than the maximum, replace the crankshaft.

  10. INSPECT CRANKSHAFT OIL CLEARANCE


    1. Install the crankshaft bearings Click here.

    2. Install the crankshaft thrust washers Click here.

    3. Clean each main journal and crankshaft bearing.

    4. A01W2WYE01
      Text in Illustration
      *a Plastigage

      Place the crankshaft on the cylinder block sub-assembly.

    5. Lay a strip of Plastigage across each journal.

    6. Install the crankshaft bearing caps Click here.

      Note

      Do not turn the crankshaft.

    7. Remove the crankshaft bearing caps Click here.

    8. A01W4N4E01
      Text in Illustration
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      0.017 to 0.040 mm (0.000669 to 0.00157 in.)
      Maximum Oil Clearance
      0.05 mm (0.00197 in.)

      Note

      Remove the Plastigage completely after the measurement.

      If the oil clearance is more than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

      Tech Tips

      If replacing a crankshaft bearing, select a new one with the same number. If the number of the crankshaft bearing cannot be determined, select the correct crankshaft bearing by adding together the numbers imprinted on the cylinder block sub-assembly and crankshaft. Then refer to the following table for the appropriate crankshaft bearing number. There are 4 sizes of standard bearings, marked "1", "2", "3" or "4" accordingly.

      A01W1I8E02
      Text in Illustration
      *a Cylinder Block Number Mark (A) *b Crankshaft Number Mark (B)
      *c Diameter Mark - -
      EXAMPLE
      Cylinder block sub-assembly (A) "3" + Crankshaft (B) "4" = Total "7" Select the crankshaft bearing marked "3".
      Crankshaft Bearing Chart
      (A) + (B) Use Crankshaft Bearing
      0 to 2 1
      3 to 5 2
      6 to 8 3
      9 to 11 4
      Standard Cylinder Block Journal Inside Diameter (A)
      Mark Specified Condition
      0 59.000 to 59.002 mm (2.32283 to 2.32291 in.)
      1 59.003 to 59.004 mm (2.32295 to 2.32299 in.)
      2 59.005 to 59.006 mm (2.32303 to 2.32307 in.)
      3 59.007 to 59.009 mm (2.32311 to 2.32318 in.)
      4 59.010 to 59.011 mm (2.32322 to 2.32326 in.)
      5 59.012 to 59.013 mm (2.32330 to 2.32334 in.)
      6 59.014 to 59.016 mm (2.32338 to 2.32346 in.)
      Standard Crankshaft Main Journal Diameter (B)
      Mark Specified Condition
      0 54.999 to 55.000 mm (2.16531 to 2.16535 in.)
      1 54.997 to 54.998 mm (2.16523 to 2.16527 in.)
      2 54.995 to 54.996 mm (2.16515 to 2.16519 in.)
      3 54.993 to 54.994 mm (2.16507 to 2.16511 in.)
      4 54.991 to 54.992 mm (2.16500 to 2.16504 in.)
      5 54.988 to 54.990 mm (2.16488 to 2.16496 in.)
      Standard Crankshaft Bearing Center Wall Thickness
      Mark Specified Condition
      1 1.992 to 1.995 mm (0.07843 to 0.07854 in.)
      2 1.996 to 1.998 mm (0.07858 to 0.07866 in.)
      3 1.999 to 2.001 mm (0.07870 to 0.07878 in.)
      4 2.002 to 2.004 mm (0.07882 to 0.07890 in.)

      1. Perform the inspection for each journal.

  11. INSPECT CRANKSHAFT BEARING CAP BOLT


    1. A01W4SBE01
      Text in Illustration
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard Diameter
      9.77 to 9.96 mm (0.385 to 0.392 in.)
      Minimum Diameter
      9.1 mm (0.358 in.)
      Measurement Point (Distance from the Seat)
      58.5 mm (2.30 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the crankshaft bearing cap bolt. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the crankshaft bearing cap bolt with a new one.

  12. INSPECT CONNECTING ROD BOLT


    1. A01W1NCE26
      Text in Illustration
      *a Measurement Area

      Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration.

      Standard Diameter
      8.5 to 8.6 mm (0.335 to 0.339 in.)
      Minimum Diameter
      8.3 mm (0.327 in.)

      Tech Tips


      • Diameter measurements should be done at several points.

      • If the diameter is less than the minimum, replace the connecting rod bolt. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the connecting rod bolt with a new one.

  13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01W3IKE02
      Text in Illustration
      *a Pin

      Push the check valve with a pin to check if it is stuck.

      If the check valve is stuck, replace the No. 1 oil nozzle sub-assembly.

    2. Push the check valve with a pin to check if it moves smoothly.

      If the check valve does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly.

    3. A01W54HE02

      Apply air to (A). Check that air does not leak through (B).

      If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

    4. A01W5OJE02
      Text in Illustration
      *a Pin

      Push the check valve with a pin while applying air to (A). Check that air passes through (B).

      If air does not pass through (B), clean or replace the No. 1 oil nozzle sub-assembly.