CYLINDER BLOCK INSPECTION

PROCEDURE

1. Click here

   INSPECT CONNECTING ROD THRUST CLEARANCE

   
   
   1. 

      Using a dial indicator, measure the thrust clearance of the connecting rod while moving the connecting rod sub-assembly back and forth.

      Standard thrust clearance
      0.16 to 0.36 mm (0.0063 to 0.0142 in.)

      Maximum thrust clearance
      0.36 mm (0.0142 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod sub-assembly.

2. Click here

   INSPECT CONNECTING ROD OIL CLEARANCE

   
   
   1. 

      Confirm that the matchmarks of the connecting rod sub-assembly and connecting rod cap are aligned.

      Table 1. Text in Illustration

      *a

      Matchmark

   2. 

      Using SST, remove the 2 bolts and the connecting rod cap.

      09205-16011

   3. 

      Clean the bearing and connecting rod sub-assembly end crank pin.

      Table 2. Text in Illustration

      *a	Plastigage

   4. Check that the bearing and crank pin are not excessively worn or scratched.

   5. Lay a strip of Plastigage across the crank pin.

   6. 

      Check the front marks of the connecting rod sub-assembly and connecting rod cap, and then install the connecting rod cap onto the connecting rod sub-assembly.

      Table 3. Text in Illustration

      *a	Front Mark

   7. Apply a light coat of engine oil to the threads and contact surfaces of the bolts.

   8. 

      Using SST, temporarily tighten the bolts in several steps, and then retighten them to the specified torque.

      09205-16011

      15 N*m

      153 kgf*cm

      11 ft.*lbf

   9. 

      Mark the front of the connecting cap bolts with paint.

      Table 4. Text in Illustration

      *a	Paint Mark
      	Engine Front

   10. Retighten the cap bolts by 90° as shown in the illustration.

       Note:

       Do not turn the crankshaft when measuring.

   11. 

       Remove the connecting rod cap, and then measure the Plastigage at its widest point.

       Standard oil clearance
       0.014 to 0.038 mm (0.0006 to 0.0015 in.)

       Maximum oil clearance
       0.065 mm (0.026 in.)

       Note:

       Completely remove the Plastigage.

   12. 

       If the clearance is greater than the maximum, select and install a replacement connecting rod bearing.

       Table 5. Text in Illustration

       *a	Front Mark
       *b	Number Mark

       Table 6. Reference:

       Number Mark	Connecting Rod External Diameter mm (in.)	Center Bearing Thickness mm (in.)	Oil Clearance mm (in.)
       1	47.000 to 47.008 (1.85039 to 1.85071)	1.489 to 1.493 (0.05862 to 0.05878)	0.014 to 0.038 (0.00055 to 0.00150)
       2	47.009 to 47.016 (1.85075 to 1.85102)	1.494 to 1.497 (0.05882 to 0.05894)	↑
       3	47.017 to 47.024 (1.85106 to 1.85134)	1.498 to 1.501 (0.05898 to 0.05909)	↑

3. Click here

   INSPECT CRANKSHAFT THRUST CLEARANCE

   
   
   1. 

      Using a dial indicator, measure the thrust clearance of the crankshaft while moving a screwdriver back and forth between the crankshaft and the crankshaft bearing cap.

      Standard thrust clearance
      0.04 to 0.24 mm (0.0016 to 0.0094 in.)

      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is greater than the maximum, replace the thrust washer or crankshaft.

      Thrust washer thickness
      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

4. Click here

   INSPECT CYLINDER BLOCK FOR FLATNESS

   
   
   1. 

      Using a precision straightedge and feeler gauge, measure the warpage of the top surface of the cylinder block sub-assembly.

      Maximum warpage
      0.05 mm (0.0020 in.)

5. Click here

   INSPECT CYLINDER BORE

   
   
   1. 

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

      Table 7. Text in Illustration

      *a	Engine Front
      *b	Thrust Direction
      *c	Axial Direction
      *d	Center

      Standard diameter
      73.000 to 73.013 mm (2.8740 to 2.8745 in.)

      Maximum diameter
      73.133 mm (2.8792 in.)

      Tip:

      If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.

6. Click here

   INSPECT WITH PIN PISTON SUB-ASSEMBLY

   
   
   1. 

      Table 8.

      *1

      50.4 mm

      Using a micrometer, measure the piston diameter at right angles to the piston pin center line, and at a position 50.4 mm (1.984 in.) from the top of the piston head.

      Piston diameter
      72.936 to 72.988 mm (2.8715 to 2.8735 in.)

      Tip:

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

   2. 

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

      Standard Piston Pin Hole Diameter
      Item Specified Condition mm (in.) Mark A 27.019 to 27.023 (1.06374 to 1.06390) Mark B 27.023 to 27.027 (1.06390 to 1.06405) Mark C 27.027 to 27.031 (1.06405 to 1.06421)

   3. 

      Using a micrometer, measure the external diameter of the piston pin.

      Standard Piston Pin Diameter
      Item Specified Condition mm (in.) Mark A 27.008 to 27.012 (1.06331 to 1.06346) Mark B 27.012 to 27.016 (1.06346 to 1.06362) Mark C 27.016 to 27.020 (1.06362 to 1.06378)

      Note:

      Do not change the combinations of the pistons and piston pins so that they can be returned to their original locations when reassembling.

7. Click here

   INSPECT PISTON CLEARANCE

   
   

   1. Subtract the piston diameter measurement from the cylinder bore minimum diameter measurement to calculate the piston clearance.

      Standard oil clearance
      0.050 to 0.077 mm (0.0020 to 0.0030 in.)

      Maximum oil clearance
      0.08 mm (0.0032 in.)

      If the piston clearance is greater than the maximum, replace the piston or cylinder block sub-assembly.

   2. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

      Standard oil clearance
      0.007 to 0.015 (0.0003 to 0.0006 in.)

      Maximum oil clearance
      0.05 mm (0.0020 in.)

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

8. Click here

   INSPECT RING GROOVE CLEARANCE

   
   
   1. 

      Using a feeler gauge, measure the clearance between the piston ring and ring groove all around the piston.

      Standard Ring Groove Clearance
      Ring Standard mm (in.) No. 1 0.110 to 0.150 (0.0043 to 0.0059) No. 2 0.070 to 0.110 (0.0028 to 0.0043) Oil 0.030 to 0.070 (0.0012 to 0.0028)

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

9. Click here

   INSPECT PISTON RING END GAP

   
   
   1. 

      Using the piston, push the piston ring until it is 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.

      Table 9. Text in Illustration

      *1	Piston Ring

   2. 

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Ring Standard mm (in.) Maximum mm (in.) No. 1 0.17 to 0.27 (0.0067 to 0.0106) 0.42 (0.0165) No. 2 0.61 to 0.71 (0.0240 to 0.0280) 0.80 (0.0315) Oil 0.10 to 0.30 (0.0039 to 0.0118) 0.70 (0.0276)

      If the end gap is greater than the maximum, replace the piston ring and oil ring.

10. Click here

    INSPECT CONNECTING ROD SUB-ASSEMBLY

    
    
    1. 

       Using a caliper gauge, measure the internal diameter of the connecting rod sub-assembly.

       Standard Connecting Rod Internal Diameter
       Item Specified Condition mm (in.) Mark A 27.022 to 27.026 (1.06386 to 1.06401) Mark B 27.026 to 27.030 (1.06401 to 1.06417) Mark C 27.030 to 27.034 (1.06417 to 1.06433)

       If the diameter is greater than the maximum, replace the connecting rod sub-assembly.

    2. 

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

       
       

       1. Check the misalignment.

          Maximum misalignment
          0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

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

       2. 

          Check the twist.

          Maximum twist
          0.05 mm (0.002 in.) per 100 mm (3.94 in.)

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

11. Click here

    INSPECT CONNECTING ROD BOLT

    
    
    1. 

       Using a vernier caliper, measure the diameter at the position illustrated.

       Standard diameter
       6.6 to 6.7 mm (0.260 to 0.264 in.)

       Minimum diameter
       6.4 mm (0.252 in.)

       If the diameter is less than the minimum, replace the connecting rod bolt.

12. Click here

    INSPECT CRANKSHAFT

    
    
    1. 

       Inspect the circle runout.

       
       

       1. Using a dial indicator and V-blocks, measure the circle runout of the crankshaft.

          Maximum circle runout
          0.015 mm (0.0006 in.)

          If the circle runout is greater than the maximum, replace the crankshaft.

    2. 

       Inspect the diameter.

       
       

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

          Diameter
          45.988 to 46.000 mm (1.8105 to 1.8110 in.)

       2. Calculate the taper and out-of-roundness of the main journal.

          Maximum taper and out-of-round
          0.02 mm (0.0008 in.)

          If the taper and out-of-roundness are greater than the maximum, replace the crankshaft.

       3. 

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

          Diameter
          43.992 to 44.000 mm (1.7320 to 1.7323 in.)

       4. Calculate the taper and out-of-roundness of the crank pin.

          Maximum taper and out-of-round
          0.02 mm (0.0008 in.)

          If the taper and out-of-roundness are greater than the maximum, replace the crankshaft.

13. Click here

    INSPECT CRANKSHAFT BEARING CAP SET BOLT

    
    
    1. 

       Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration.

       Table 10. Text in Illustration

       *a	Measurement Area

       Standard diameter
       10.8 to 11.0 mm (0.425 to 0.433 in.)

       Minimum diameter
       10.6 mm (0.417 in.)

       If the diameter is less than the minimum, replace the crankshaft bearing cap bolt.

14. Click here

    INSPECT CRANKSHAFT OIL CLEARANCE

    
    
    1. 

       Clean the main journal and crankshaft bearing.

       Table 11. Text in Illustration

       *a	Oil Groove	*b	Upper Bearing
       *c	Block Side	*d	Lower Bearing
       *e	Cap Side	-	-

    2. Install the upper bearing with the oil groove onto the cylinder block sub-assembly, the lower bearing onto the bearing cap.

       Note:

       Do not apply engine oil to the contact surface of the cylinder block sub-assembly or the back side of the crankshaft bearing.

       Tip:

       Mass production parts do not have identification marks. If reusing a mass production part, measure the clearance of both sides so that the bearing is in the center of the bearing cap.

       Specified clearance
       A - B = within 0.8 mm (0.032 in.)

    3. Install the crankshaft onto the cylinder block sub-assembly.

    4. 

       Lay a strip of Plastigage across the crankshaft journal.

       Table 12. Text in Illustration

       *a	Plastigage

    5. 

       Examine the front marks and imprinted numbers and check that the sequence is as shown in the illustration. Then, install the bearing caps onto the cylinder block sub-assembly.

       Table 13. Text in Illustration

       Engine Front

    6. 

       Apply a light coat of engine oil to the threads and contact surface of the bolt.

    7. Using several steps, temporarily tighten the bolts in the order shown in the illustration, and tighten them to the specified torque (step "g").

       60 N*m

       612 kgf*cm

       44 ft.*lbf

    8. 

       Mark the front of the crankshaft bearing cap bolts with paint.

       Table 14. Text in Illustration

       *a	Paint Mark
       	Engine Front

    9. Retighten the bearing cap bolts by 90° in the same order as step "g".

    10. Check that each paint mark is now at a 90° angle from the front.

        Note:

        Do not turn the crankshaft when measuring.

    11. 

        Remove the bearing cap, and then measure the Plastigage at its widest point.

        Standard oil clearance
        0.010 to 0.023 mm (0.0004 to 0.0009 in.)

        Maximum oil clearance
        0.07 mm (0.0028 in.)

        Note:

        Completely remove the Plastigage.

    12. 

        If the clearance is greater than the maximum, select and install a replacement crankshaft bearing.

        Table 15. Text in Illustration

        *a	Cylinder Block Number	*b	Crank Journal Number
        *c	Bearing Number	-	-

        Tip:
        

        • To select the correct bearing size, calculate the bearing number by adding together the numbers imprinted on the cylinder block sub-assembly and crank journal.

        • Example:

          Imprinted number on the cylinder block is 3.

          Imprinted number on the crank journal is 4.

          3 + 4 = 7

          Select a bearing with the bearing number 3.

          Number	Cylinder Block Main Journal Bore Diameter mm (in.)	Crank Main Journal Diameter mm (in.)
          0	50.000 to 50.002 (1.96850 to 1.96858)	45.999 to 46.000 (1.81098 to 1.81102)
          1	50.003 to 50.004 (1.96862 to 1.96866)	45.997 to 45.998 (1.81091 to 1.81094)
          2	50.005 to 50.006 (1.96870 to 1.96874)	45.995 to 45.996 (1.81083 to 1.81087)
          3	50.007 to 50.009 (1.96878 to 1.96886)	45.993 to 45.994 (1.81075 to 1.81079)
          4	50.010 to 50.011 (1.96890 to 1.96894)	45.991 to 45.992 (1.81067 to 1.81071)
          5	50.012 to 50.013 (1.96898 to 1.96902)	45.998 to 45.990 (1.81094 to 1.81063)
          6	50.014 to 50.015 (1.96906 to 1.96909)	-

          Cylinder Block Number + Crank Journal Number	Bearing Number	Center Bearing Thickness mm (in.)	Oil Clearance mm (in.)
          0 to 2	1	1.992 to 1.995 (0.07843 to 0.07854)	0.010 to 0.023 (0.00039 to 0.00091)
          3 to 5	2	1.996 to 1.998 (0.07858 to 0.07866)	↑
          6 to 8	3	1.999 to 2.001 (0.07870 to 0.07878)	↑
          9 to 11	4	2.002 to 2.004 (0.07882 to 0.07890)	↑