CYLINDER BLOCK INSPECTION

PROCEDURE


  1. INSPECT CRANKSHAFT


    1. A01VI3G

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

      Maximum circle runout
      0.02 mm (0.000787 in.)

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

    2. A01VKD3E01

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

      Standard diameter
      47.988 to 48.000 mm (1.88929 to 1.88976 in.)

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

    3. Check each main journal for taper and distortion as shown in the illustration.

      Maximum taper and distortion
      0.003 mm (0.000118 in.)

      If the taper and distortion are greater than the maximum, replace the crankshaft.

      Standard Diameter (Reference)
      Mark Specified Condition
      0 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
      1 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
      2 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
      3 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
      4 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
      5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
    4. A01VK4K

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

      Standard diameter
      41.992 to 42.000 mm (1.6532 to 1.6535 in.)

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

    5. Inspect each crank pin for taper and distortion as shown in the illustration.

      Maximum taper and distortion
      0.003 mm (0.000118 in.)

      If the taper and distortion are greater than the maximum, replace the crankshaft.

  2. INSPECT CYLINDER BLOCK FOR WARPAGE


    1. A01VHDN

      Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.

      Maximum warpage
      0.05 mm (0.00197 in.)

      If the warpage is greater than the maximum, replace the cylinder block.

  3. INSPECT CYLINDER BORE


    1. A01VKG3E09
      Text in Illustration
      *a Thrust Direction
      *b Axial Direction
      A01VL3H Engine Front

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

      Standard diameter
      72.500 to 72.513 mm (2.8543 to 2.8548 in.)
      Maximum diameter
      72.63 mm (2.8594 in.)

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

  4. INSPECT PISTON


    1. A01VKUT

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

    2. A01VKX4

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

    3. A01VKZJ

      Using a brush and solvent, thoroughly clean the piston.

      Note

      Do not use a wire brush.

    4. A01VJOEE01
      Text in Illustration
      *a Front Mark
      *b

      Front Mark (1): 8.8 mm (0.346 in.)

      Front Mark (1B): 9.33 mm (0.367 in)

      Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 8.8 mm (0.346 in.) or 9.33 mm (0.367 in) from the piston bottom.

      Standard piston diameter
      72.445 to 72.465 mm (2.8522 to 2.8529 in.)

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

  5. INSPECT PISTON OIL CLEARANCE


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

      Standard oil clearance
      0.035 to 0.068 mm (0.00138 to 0.00268 in.)
      Maximum oil clearance
      0.108 mm (0.00425 in.)

      If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

  6. INSPECT RING GROOVE CLEARANCE


    1. A01VIJ6

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

      Standard Ring Groove Clearance
      Item Specified Condition
      No. 1 Compression Ring 0.02 to 0.07 mm (0.0008 to 0.0028 in.)
      No. 2 Compression Ring 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
      Oil Ring (Side Rail) 0.07 to 0.15 mm (0.0028 to 0.0059 in.)

      If the groove clearance is not as specified, replace the piston. If the ring groove clearance is still not as specified even with a new piston ring set, replace the piston with pin, connecting rod and connecting rod cap.

  7. INSPECT PISTON RING END GAP


    1. A01VG0EE01
      *1 50 mm

      Using a piston, push the piston ring set a little beyond the bottom of the ring travel, 50 mm (1.97 in.) from the top of the cylinder block.

    2. A01VIYH

      Using a feeler gauge, measure the end gap.

      Standard End Gap
      Item Specified Condition
      No. 1 Compression Ring 0.18 to 0.25 mm (0.00709 to 0.00984 in.)
      No. 2 Compression Ring 0.30 to 0.42 mm (0.0118 to 0.0165 in.)
      Oil Ring (Side Rail) 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
      Maximum End Gap
      Item Specified Condition
      No. 1 Compression Ring 0.45 mm (0.0177 in.)
      No. 2 Compression Ring 0.65 mm (0.0256 in.)
      Oil Ring (Side Rail) 0.55 mm (0.0217 in.)

      If the end gap is greater than the maximum, replace the piston ring set. If the end gap is greater than the maximum, even with a new piston ring set, replace the cylinder block.

  8. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01VKU3

      Install the crankshaft bearing cap Click here.

    2. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.04 to 0.24 mm (0.00157 to 0.00945 in.)
      Maximum thrust clearance
      0.28 mm (0.0110 in.)

      If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

      Tech Tips

      The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

  9. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01VM8N

      Install the connecting rod cap Click here.

    2. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.1 to 0.5 mm (0.00394 to 0.0197 in.)
      Maximum thrust clearance
      0.5 mm (0.0197 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.

  10. INSPECT CRANKSHAFT OIL CLEARANCE


    1. A01VGUIE02
      Text in Illustration
      *1 Plastigage

      Check the crank journal and crankshaft bearing for pitting and scratches.

    2. Install the crankshaft bearing Click here.

    3. Place the crankshaft on the cylinder block.

    4. Lay a strip of Plastigage across each journal.

    5. Examine the front marks and numbers and install the crankshaft bearing caps on the cylinder block.

      Tech Tips

      A number is marked on each crankshaft bearing cap to indicate the installation position.

    6. Install the crankshaft bearing cap Click here.

      Note

      Do not turn the crankshaft.

    7. Remove the crankshaft bearing caps Click here.

    8. Measure the Plastigage at its widest point.

      A01VFZJE01
      Text in Illustration
      *1 Plastigage
      *a Number Marks
      Standard oil clearance
      0.019 to 0.043 mm (0.000748 to 0.00169 in.)
      Maximum oil clearance
      0.049 mm (0.00192 in.)

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

      Note

      Remove the Plastigage completely after the measurement.

      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, calculate the correct crankshaft bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new crankshaft bearing with the calculated number according to the chart below. There are 4 sizes of standard bearings, marked "2", "3", "4" and "5" accordingly.

      • EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "4")

      Cylinder block + Crankshaft 0 to 2 3 to 5 6 to 8 9 to 11
      Bearing to be used "2" "3" "4" "5"
      Standard Cylinder Block Journal Bore Diameter
      Mark Specified Condition
      0 52.000 to 52.002 mm (2.04724 to 2.04732 in.)
      1 52.003 to 52.004 mm (2.04736 to 2.04740 in.)
      2 52.005 to 52.006 mm (2.04744 to 2.04748 in.)
      3 52.007 to 52.009 mm (2.04752 to 2.04759 in.)
      4 52.010 to 52.011 mm (2.04763 to 2.04767 in.)
      5 52.012 to 52.013 mm (2.04771 to 2.04775 in.)
      6 52.014 to 52.016 mm (2.04779 to 2.04787 in.)
      Standard Crankshaft Journal Diameter
      Mark Specified Condition
      0 47.999 to 48.000 mm (1.88972 to 1.88976 in.)
      1 47.997 to 47.998 mm (1.88964 to 1.88968 in.)
      2 47.995 to 47.996 mm (1.88956 to 1.88960 in.)
      3 47.993 to 47.994 mm (1.88948 to 1.88952 in.)
      4 47.991 to 47.992 mm (1.88941 to 1.88945 in.)
      5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)
      Standard Bearing Center Wall Thickness
      Mark Specified Condition
      2 1.994 to 1.997 mm (0.07850 to 0.07862 in.)
      3 1.998 to 2.000 mm (0.07866 to 0.07874 in.)
      4 2.001 to 2.003 mm (0.07878 to 0.07886 in.)
      5 2.004 to 2.006 mm (0.07890 to 0.07898 in.)

  11. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01VGFZE02
      Text in Illustration
      *1 Plastigage

      Clean the crank pin and connecting rod bearing.

    2. Check the crank pin and connecting rod bearing for pitting and scratches.

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

    4. A01VJV4E07
      Text in Illustration
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing forward.

    5. Install the connecting rod cap Click here.

      Note

      Do not turn the crankshaft.

    6. Remove the 2 bolts and connecting rod cap Click here.

    7. A01VF7BE01
      Text in Illustration
      *1 Plastigage
      *a Mark

      Measure the Plastigage at its widest point.

      Standard oil clearance
      0.020 to 0.052 mm (0.000787 to 0.002047 in.)
      Maximum oil clearance
      0.055 mm (0.00217 in.)

      If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

      Note

      Completely remove the Plastigage after the measurement.

      Tech Tips

      If replacing a connecting rod bearing, replace it with one that has the same number as its respective connecting rod cap. Each connecting rod bearing's standard thickness is indicated by mark 1, 2, or 3 on its surface.

      Standard Connecting Rod Large End Bore Diameter
      Mark Specified Condition
      Mark 1 45.000 to 45.008 mm (1.77165 to 1.77197 in.)
      Mark 2 45.009 to 45.016 mm (1.77200 to 1.77228 in.)
      Mark 3 45.017 to 45.024 mm (1.77232 to 1.77259 in.)
      Standard Connecting Rod Bearing Thickness
      Mark Specified Condition
      Mark 1 1.492 to 1.495 mm (0.0587 to 0.05886 in.)
      Mark 2 1.496 to 1.498 mm (0.05890 to 0.05898 in.)
      Mark 3 1.499 to 1.501 mm (0.05902 to 0.0591 in.)
      Standard Crankshaft Pin Diameter
      Mark Specified Condition
      Mark 1, 2, 3 41.992 to 42.000 mm (1.6532 to 1.6535 in.)

  12. INSPECT CONNECTING ROD BOLT


    1. A01VDLME13
      Text in Illustration
      *a Measurement Area

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

      Standard diameter
      6.6 to 6.7 mm (0.2598 to 0.2638 in.)
      Minimum diameter
      6.4 mm (0.2520 in.)

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

  13. INSPECT CRANKSHAFT BEARING CAP SET BOLT


    1. A01VJ3HE05
      Text in Illustration
      *a Measurement Length

      Using a vernier caliper, measure the length of the crankshaft bearing cap set bolts.

      Standard length
      75.3 to 76.7 mm (2.965 to 3.020 in.)
      Maximum length
      77.2 mm (3.039 in.)

      If the length is greater than the maximum, replace the crankshaft bearing cap set bolt.

    2. A01VF2WE05
      Text in Illustration
      *a Measurement Area

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

      Standard diameter
      9.94 to 9.96 mm (0.3914 to 0.3921 in.)
      Minimum diameter
      9.6 mm (0.377 in.)

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

  14. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Check the No. 1 oil nozzle sub-assembly for damage or clogging.

      Tech Tips

      If there is damage or clogging, replace the No. 1 oil nozzle sub-assembly.