CYLINDER BLOCK INSPECTION

PROCEDURE


  1. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. B007191

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

      Maximum Warpage
      0.05 mm (0.00197 in.)

      Tech Tips

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

  2. INSPECT CYLINDER BORE


    1. B006ZPKC01
      *a Thrust Direction
      *b Axial Direction
      *c 10 mm (0.394 in.)
      *d Center
      B006Z38 Front of Engine

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

      Reference Diameter (New Parts)
      87.500 to 87.513 mm (3.44488 to 3.44539 in.)
      Maximum Diameter
      87.63 mm (3.44999 in.)

      Tech Tips

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

  3. INSPECT PISTON


    1. B006YPB

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

    2. B006ZX1

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

    3. B006ZAM

      Using a brush and solvent, thoroughly clean the piston.

      Note

      Do not use a wire brush.

    4. B006ZB1C01
      *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
      10.5 mm (0.413 in.)
      Standard Piston Diameter (New Parts)
      87.472 to 87.502 mm (3.44377 to 3.44495 in.)

      Tech Tips

      If the diameter is less than the minimum, replace the piston and piston pin as a set.

  4. INSPECT PISTON OIL CLEARANCE


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

      Reference Oil Clearance (New Parts)
      -0.002 to 0.041 mm (-0.0000787 to 0.00161 in.)
      Maximum Oil Clearance
      0.081 mm (0.00319 in.)

      Tech Tips

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

  5. INSPECT RING GROOVE CLEARANCE


    1. B006Y6L

      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 0.065 mm (0.000787 to 0.00256 in.)
      No. 2 compression ring 0.020 to 0.055 mm (0.000787 to 0.00217 in.)
      Oil ring 0.060 to 0.110 mm (0.00236 to 0.00433 in.)

      Tech Tips

      If the groove clearance is not as specified, replace the piston and piston pin as a set.

  6. INSPECT PISTON RING END GAP


    1. B006ZYMC01
      *a Piston Ring
      *b 70 mm

      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, 70 mm (2.76 in.) from the top of the cylinder block sub-assembly.

    3. B0070PU

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 compression ring 0.21 to 0.24 mm (0.00827 to 0.00945 in.)
      No. 2 compression ring 0.50 to 0.55 mm (0.0197 to 0.0217 in.)
      Oil ring 0.10 to 0.30 mm (0.00394 to 0.0118 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 compression ring 0.49 mm (0.0193 in.)
      No. 2 compression ring 0.80 mm (0.0315 in.)
      Oil ring 0.55 mm (0.0217 in.)

      Tech Tips

      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

    Tech Tips

    When replacing the piston and piston pin with supply parts, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.


    1. Confirm each mark on the piston, piston pin and connecting rod.

      B0070JPC01
      *a Front Mark *b Piston Pin Hole Inside Diameter Mark
      *c Connecting Rod Small End Bush Inside Diameter Mark - -
    2. B0070JZ

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

      Standard Piston Pin Hole Inside Diameter
      21.006 to 21.015 mm (0.82700 to 0.82736 in.)
      Mark Specified Condition
      A 21.006 to 21.009 mm (0.82701 to 0.82712 in.)
      B 21.010 to 21.012 mm (0.82716 to 0.82724 in.)
      C 21.013 to 21.015 mm (0.82728 to 0.82736 in.)

      Tech Tips

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

    3. B00705PC01

      Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter
      21.004 to 21.013 mm (0.82693 to 0.82728 in.)
      Mark Specified Condition
      A 21.004 to 21.007 mm (0.82693 to 0.82705 in.)
      B 21.008 to 21.010 mm (0.82708 to 0.82716 in.)
      C 21.011 to 21.013 mm (0.82720 to 0.82728 in.)

      Tech Tips

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

      Measurement Position
      Measurement Position Piston Pin Position
      a 5 mm (0.197 in.) from side edge
      b 24.5 mm (0.965 in.) from side edge
    4. B006X0R

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

      Standard Connecting Rod Small End Bush Inside Diameter
      21.012 to 21.021 mm (0.82724 to 0.82760 in.)
      Mark Specified Condition
      A 21.012 to 21.015 mm (0.82724 to 0.82736 in.)
      B 21.016 to 21.018 mm (0.82740 to 0.82748 in.)
      C 21.019 to 21.021 mm (0.82752 to 0.82760 in.)

      Tech Tips

      If the inside 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 0.005 mm (-0.0000394 to 0.000197 in.)
      Maximum Oil Clearance
      0.015 mm (0.000591 in.)

      Tech Tips

      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
      0.021 mm (0.000827 in.)

      Tech Tips

      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


    1. B006ZAT

      Using a connecting rod aligner and feeler gauge, check the connecting rod 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.

      2. B006XIX

        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.

  9. INSPECT CRANKSHAFT


    1. Inspect for runout.


      1. Clean the crank journal.

      2. Place the crankshaft on V-blocks.

      3. B006ZUP

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

        Maximum Runout
        0.03 mm (0.00118 in.)

        Tech Tips

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

    2. Inspect the main journals.


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

        Standard Main Journal Diameter
        55.988 to 56.000 mm (2.20425 to 2.20472 in.)

        Tech Tips

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

      2. B00700R

        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.)

        Tech Tips

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

    3. Inspect the crank pins.


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

        Standard Crank Pin Diameter
        47.992 to 48.000 mm (1.88945 to 1.88976 in.)

        Tech Tips

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

      2. B006ZBZ

        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.)

        Tech Tips

        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. Place the crankshaft on the cylinder block sub-assembly.

    4. B0071NJC01
      *a Plastigage

      Lay a strip of Plastigage across each journal.

    5. Install the crankshaft bearing caps.

      Click here

      Note

      Do not turn the crankshaft.

    6. Remove the crankshaft bearing caps.

      Click here

    7. B006ZZUC01
      *a Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      for No. 3 journal
      0.020 to 0.043 mm (0.000787 to 0.00169 in.)
      except No. 3 journal
      0.014 to 0.037 mm (0.000551 to 0.00146 in.)
      Maximum Oil Clearance
      for No. 3 journal
      0.044 mm (0.00173 in.)
      except No. 3 journal
      0.048 mm (0.00189 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.

    8. Perform the inspection for each journal.

  11. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. B006XXBC02
      *a Measurement Area (B)
      *b 5.0 mm (0.197 in.)
      *c 10 mm (0.394 in.)
      B006Z38 Measurement Location (A)

      Using a vernier caliper, measure the outer diameter at position (A) shown in the illustration.

      Standard Diameter
      10.73 to 10.97 mm (0.422 to 0.432 in.)

    2. Using a vernier caliper, measure the outer diameter within range (B) shown in the illustration at several locations.

      Tech Tips


      • Perform the measurement within range (B) at several locations.

      • If the threads of the crankshaft bearing cap set bolt are damaged, replace the bolt with a new one.

    3. Calculate the difference between the measurement at position (A) and position (B).

      Minimum Diameter
      The outer diameter difference is 0.3 mm (0.0118 in.)

      Tech Tips


      • Outer Diameter Difference = Position (A) Outer Diameter - Position (B) Outer Diameter (Smallest Value)

      • If the outer diameter is below the minimum, the engine may be damaged.

        Therefore, replace the crankshaft bearing cap set bolt with a new one.

  12. INSPECT CONNECTING ROD BOLT


    1. B006ZEZC02
      *a Measurement Area (B)
      *b 5.0 mm (0.197 in.)
      *c 10 mm (0.394 in.)
      B006Z38 Measurement Location (A)

      Using a vernier caliper, measure the outer diameter at position (A) shown in the illustration.

      Standard Diameter
      8.36 to 8.5 mm (0.329 to 0.335 in.)

    2. Using a vernier caliper, measure the outer diameter within range (B) shown in the illustration at several locations.

      Tech Tips


      • Perform the measurement within range (B) at several locations.

      • If the threads of the connecting rod bolt are damaged, replace the bolt with a new one.

    3. Calculate the difference between the measurement at position (A) and position (B).

      Minimum Diameter
      The outer diameter difference is 0.05 mm (0.00197 in.)

      Tech Tips


      • Outer Diameter Difference = Position (A) Outer Diameter - Position (B) Outer Diameter (Smallest Value)

      • If the outer diameter is below the minimum, the engine may be damaged.

        Therefore, replace the connecting rod bolt with a new one.

  13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B006YOCC01
      *a Air

      Blow air into the (A) side, and check that air passes through (B) easily.

      Tech Tips

      If the result is not as specified, replace the No. 1 oil nozzle sub-assembly.

  14. INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. B006YK8C01
      *a Air

      Blow air into the (A) side, and check that air passes through (B) easily.

      Tech Tips

      If the result is not as specified, replace the No. 2 oil nozzle sub-assembly.